Pleated filtration media, media packs, filter elements, and methods for filtering fluids

ABSTRACT

Pleated filtration media, media packs, filter elements, and methods for filtering fluid are provided which contain three dimensional flutes in the media surface, the flutes configured to improve filter performance. In certain embodiments the flutes have defined peaks that reduce masking between adjacent pleats, the flutes have ridges along their length to modify flute cross sectional geometry, and/or the flutes provide for volume asymmetry across the media.

This application is a continuation of U.S. application Ser. No.14/708,993, filed May 11, 2015, which is a continuation of U.S.application Ser. No. 12/508,944, filed Jul. 24, 2009, which claims thebenefit of U.S. Provisional Application No. 61/083,785, filed Jul. 25,2008, the contents of which are herein incorporated by reference intheir entirety.

FIELD OF THE INVENTION

The present invention relates to pleated filtration media, pleatedfiltration media packs, filter elements, and methods for filteringfluids.

BACKGROUND

Fluid streams, such as air and liquid, carry contaminant materialtherein. In many instances, it is desired to filter some or all of thecontaminant material from the fluid stream. For example, air streams toengines for motorized vehicles or for power generation equipment, airand gas streams to gas turbine systems, air and gas streams to variouscombustion furnaces, and air and gas streams to heat exchangers (e.g.,heating and air conditioning) carry particulate contaminants that shouldoften be filtered. Liquid streams in engine lube systems, hydraulicsystems, coolant systems and fuel systems, can also carry contaminantsthat should be filtered. It is preferred for such systems that selectedcontaminant material be removed from (or have its level reduced in) thefluid. A variety of fluid filters (gas or liquid filters) have beendeveloped for contaminant reduction. In general, however, continuedimprovements are sought.

SUMMARY

Pleated filtration media has been in use for many years, and is widelyadopted for fluid filtration applications, including gas and liquidfiltration. Pleated filtration media provides a relatively large mediasurface area, in a given volume, by folding the media back and forthsuch that a large amount of media can be arranged in a relatively smallvolume.

Pleated media can be assembled into numerous shapes and configurations,including panel filters and cylindrical filters. In panel filters,pleated media typically extends in a planar or panel configurationhaving a first face of the pleated media formed from a first set ofpleat folds (also called pleat tips) and a second face of the pleatedmedia formed from a second set of pleat folds (also called pleat tips).The first and second faces formed by the pleat folds are generallyparallel. Fluid flows into the panel filter through one face and out ofthe panel filter through the other face.

In cylindrical filters, pleated media is generally formed into a tube,with a first face of the pleated media (formed by a first set of pleatfolds) creating an interior face, and the second face of the pleatedmedia (formed by a second set of pleat folds) forming an outside face.In the case of a cylindrical filter for air filtration, air typicallyflows into the filter element from the outside face to the interior face(or vice versa in what are sometimes referred to as reverse flowfilters).

Pleated media packs are often formed from continuous or rolled webs offilter media, with the pleats formed transverse to the machine directionof the media. The machine direction of the media generally refers to thecontinuous direction of the media. The pleat folds, therefore, aregenerally transverse to the machine or continuous direction of the mediain order to create the three-dimension network. In general, a first setof pleat folds forms a first face of the media and a second set of pleatfolds forms a second face of the media.

One challenge to designing filter elements containing pleated filtermedia is that as the number of pleats within a given volume increases,an undesirable level of fluid flow restriction can occur with priorpleated media. This restriction occurs as the pleats become too close toeach other and interfere with each other during filtration. For example,with prior pleated media constructions, pleats can be so close togetherthat it is difficult for a fluid to enter the area between the pleats.Due to this restriction, the media is modified in some prior pleatedfilters to create an uneven surface with raised areas of shallowrepeating arcs along the media surface. Sometimes the media is embossedto create these repeating arcs. The shallow repeating arcs can be formedby running the media through the nips of corrugation rollers. As pleatshaving this uneven surface become pressed toward one another, the raisedareas on the media help maintain fluid flow between pleat surfaces byforming channels aiding fluid flow.

The present invention is directed, in part, to pleated filtration mediaand filtration media pleat packs that contain flutes extending betweenthe pleat folds (example flutes are shown in cross section, for example,at FIGS. 5A and 5B, described below). The flutes are three dimensionalstructures formed in the filtration media that provide advantageous flowpaths along the pleat surfaces, allow for advantageous flow of fluidsthrough the media, and provide for efficient contaminant removal. Thus,the pleated media containing flutes is structured so as to provideimproved filtration performance under certain conditions.

Advantages of pleated media containing flutes include, for example, theability to reduce contact between media surfaces while preserving mediaintegrity and performance; the ability to create media packs withdifferent open areas or volumes on the upstream and downstream portions(thereby affecting performance of some media arrangements), the abilityto have high pleat counts while preserving filtration performance,and/or the ability to make relatively compact, efficient, filterelements.

More specifically, in certain embodiments, fluted media made inaccordance with teachings of the present invention can significantlydiminish masking between layers of pleated media, while also promotingefficient flow of fluids through the media. The flutes formed in themedia typically have peaks where each flute can make contact withopposed pleat surfaces, which generally also have flutes with peaks. Theflute peaks will contact one another in some embodiments along some orall of the length of the flute, but in other implementations the flutepeaks will not come in contact with other flutes or flute peaks.

The flute peaks are typically characterized by a sharp radius or adefined tip that reduces masking between pleats. As used herein, maskingrefers to the area of proximity between the media sheets where there isa lack of substantial pressure difference across the media. In general,masking is experienced at the location in the media where there is closeproximity or contact to another media sheet or flow bounding surface.This close proximity can result in resistance to flow through the mediaat that location. As a result, masked media is not useful to thefiltration performance of filtration media.

Accordingly, it is desirable to reduce masking so as to increase theamount of filtration media available for filtration. Reduction inmasking increases the dust storage capacity of the filtration mediapleat pack, increases the throughput of fluids through the filtrationmedia for a given pressure drop, and/or decreases the pressure drop ofthe filtration media pleat pack for a given overall fluid flow rate.Flutes in the pleated media made in accordance with the teachings of thepresent invention allow for a reduction in masking of the media. Thisreduction in masking occurs in large part as a result of creating flutepeaks, and changing their shape and location, as described herein. Forexample, in some embodiments of the invention the flute peaks have tipsthat extend beyond the general profile of the adjacent flute.

Specific further structural aspects of the flutes include, in someembodiments, ridges running along all or part of the lengths of theflutes. As used herein, a ridge is generally a defined bend, crease, ordeformation in the media along some or all of the length of a flute.More specifically, a ridge can be a region of transition betweensubstantially differently sloped media portions within the profile of asection of fluted media. The transition is typically relatively abrupt.Under normal usage, ridges do not contact ridges from other adjacentpleats. Under normal usage, ridges occur between peaks, but ridges arenot peaks. Ridges promote efficiency of fluid flow and filtrationthrough the media packs by allowing customization and optimization ofthe cross sectional area of the flutes, increases in the amount of mediawithin a specific volume, and aiding in reduction of masking betweenflutes on opposed media surfaces. The use of ridges in the pleated mediacan actually result in increased amounts of effective or usable mediawhile having reduced masking.

In certain embodiments the filtration media pleat packs are constructedwith flutes that have different channel shapes and different openvolumes on the upstream and downstream sides of the pleats in filtrationmedia pleat packs, a property referred to herein as pleat packvolumetric asymmetry. This pleat pack volumetric asymmetry can, in someembodiments, promote contaminant material storage, flow and filtration.Pleat pack volumetric asymmetry can be particularly helpful forimproving performance in filter configurations that have shallow pleatpacks.

Specific implementations of the invention will now be described ingreater detail. In some embodiments, pleated filtration media packs madein accordance with the invention include a first set of pleat folds thatform a first face and a second set of pleat folds that form a secondface. The pleated filtration media extends between the first face andthe second face in a back and forth arrangement. At least a portion ofthe filtration media that extends between the first face and the secondface includes flutes that extend at least part way from the first faceto the second face. These flutes typically have defined flute peaksextending along part or all of the length of the flutes. Usually theflute peaks are relatively sharp, a characteristic that allows forreduced masking.

Although the peaks are sharp, in many implementations they still containa tightly curved outer surface, sometimes approximating an arc or a bendwith a radius. By providing relatively sharp peaks, the area of contactand/or proximity between media surfaces may be reduced, which results ina reduction in masking. During filtration the filtration media willtypically deflect under pressure, and the relatively sharp peaks cancontinue to reduce the contact between media surfaces, thus providing anongoing advantage with regard to reduction of masking.

As noted above, in some embodiments many of the flutes in the pleatedfiltration media pack also comprise at least one ridge between adjacentflute peaks that extends along at least a portion of the flute lengthbetween the first set of pleat folds and the second set of pleat folds.Flute ridges made in accordance with the invention can be continuous ordiscontinuous along the flute(s). For example, in some implementationsof the invention ridges will be present along the entire length of allof the flutes. Often it can be desirable to have two or more ridgesrunning along the length of each flute, with one or more ridge on eitherside of a flute peak.

However, it is also possible to have suitable flutes with significantlyfewer ridges or less extensive ridges. For example, in someimplementations at least 25% of the flutes in the pleated filtrationmedia pack have at least one ridge between adjacent flute peaks, theridge extending along at least 25% of the flute length between the firstset of pleat folds and the second set of pleat folds. Alternatively, insome implementations at least 25% of the flutes in the pleatedfiltration media pack comprise at least one ridge between adjacent flutepeaks, the ridge extending along at least 50% of the flute lengthbetween the first set of pleat folds and the second set of pleat folds.It will be understood that in some implementations at least 50% of theflutes in the pleated filtration media pack comprise at least one ridgebetween adjacent flute peaks, the ridge extending along at least 50% ofthe flute length between the first set of pleat folds and the second setof pleat folds.

Alternative designs are also contemplated and within the scope of thepresent invention. For example, in some implementations at least 25% ofthe flutes in the pleated filtration media pack have ridges betweenadjacent flute peaks that extend along at least 10% of the flute lengthbetween the first set of pleat folds and the second set of pleat folds.In some implementations at least 50% of the flutes in the pleatedfiltration media pack have at least one ridge located between adjacentflute peaks and extending along at least 10% of the flute length betweenthe first set of pleat folds and the second set of pleat folds. It willbe understood that in some implementations at least 10% of the flutes inthe pleated filtration media pack contain at least one ridge betweenadjacent flute peaks and extending along at least 10% of the flutelength between the first set of pleat folds and the second set of pleatfolds.

Alternatively, in some implementations less than 25% of the flutes inthe pleated filtration media pack have at least one ridge betweenadjacent flute peaks, the ridges extending along less than 25% of theflute length between the first set of pleat folds and the second set ofpleat folds. In some implementations less than 25% of the flutes in thepleated filtration media pack comprise at least one ridge betweenadjacent flute peaks, the ridges extending along less than 50% of theflute length between the first set of pleat folds and the second set ofpleat folds. It will be understood that in some implementations lessthan 50% of the flutes in the pleated filtration media pack comprise atleast one ridge between adjacent flute peaks, the ridges extending alongless than 50% of the flute length between the first set of pleat foldsand the second set of pleat folds.

One advantage of the present invention is that the flute geometries,typically including flute height, flute width, sharp flute peaks andoptionally one or more ridges along the flutes, allow for greateramounts of overall media surface area to be included in filtration mediapleat packs, and reduced overall masked surface area within pleat packs.This provides the capability to increase filter performance withoutincreasing filter element size. The flute designs of the presentinvention allow for increases in media while actually reducing masking,a combination that produces excellent performance results.

In terms of flute geometry, in some embodiments at least a portion ofthe flutes extending from the first set of pleat folds to the second setof pleat folds comprises a D2/D1 value that is greater than 1.0, oftenat least 1.05, and frequently at least 1.1, wherein D2 (as shown forexample in FIG. 5a ) is the media surface length corresponding to oneflute width and D1 is flute width (as shown for example in FIG. 5a ). Insome implementations D2/D1 is at least 1.15, and in otherimplementations at least 1.20. A higher D2/D1 value indicates increasesin the amount of media provided along a given flute width. In someimplementations D2/D1 is greater than 1.30, 1.40, or 1.50. Typicalranges for D2/D1 include, for example, from 1.05 to 2.0; from 1.10 to1.75; and from 1.20 to 1.50.

The flutes formed in the media typically have a width (D1, as shown forexample in FIG. 5a ) greater than their height (J, as shown for examplein FIG. 5a ). This width to height aspect ratio can be characterized as(D1/J). In most implementations the width to height aspect ratio is atleast about 2.0, generally a least 2.1, more typically at least 2.2,often at least 2.3, and optionally at least 3.0. In someimplementations, the width height ratio is greater than 2.4. Generallysuitable D1/J ratios will be less than 10, more typically less than 8,and often less than 6. Suitable D1/J ratios will be greater than 1, moreoften greater than 1.5, and usually greater than 2. Other suitable D1/Jratios include, in example implementations, greater than 4, greater than6, or greater than 8. Thus, suitable ranges include, but are not limitedto, D1/J ratios of 2 to 10, 4 to 8, and 5 to 7. However, in someimplementations flutes with extremely low D1/J ratios can be used(although such flutes are generally more difficult to manufacture). Forexample, D1/J ratios of less than 1.0, less than 0.75, and less than0.50 are possible (see, e.g. FIG. 4c ). In some implementations, flutescontaining very high or very low D1/J values have better performancethan flutes containing D1/J near values of 1.15 to 2.0. Suitable rangesof such ratios for D1/J include 2 to 8 and 0.075 to 0.500.

The three dimensional structure of flutes defines open volumes upstreamand downstream of the media for flow of fluid, as well as space forcontaminants (such as dust) to accumulate. In some embodiments thefiltration media exhibits a media volume asymmetry such that an openvolume on one side of the media is greater than an open volume on theother side of the media. These volumes can extend from an upstream faceto downstream face of the pleat pack.

Media volume asymmetry, as used herein, generally measures the mediavolume ratio of the larger media volume bounded by the flute peaks tothe smaller media volume (see FIG. 9, discussed below). In some but notall implementations, the larger media volume corresponds to the upstreamopen media volume, and the smaller media volume corresponds to thedownstream open media volume (during use the open volume may accumulatecontaminants, such as dust). In some implementations media willdemonstrate a media volume asymmetry of more than 1%, more than 3%, morethan 5%, or more than 10%. Example media constructions demonstrate amedia volume asymmetry of greater than 15%, greater than 20%, greaterthan 50%, greater than 75%, greater than 100%, greater than 150%, andgreater than 200%. Suitable media volume asymmetry ranges includes, forexample, 1% to 300%, 5% to 200%; 50% to 200%; 100% to 200%; and 100% to150%.

In addition to media volume asymmetry, the media may also demonstratemedia cross-sectional area asymmetry, which is calculated based upon across-section of the media. It will be understood that cross-sectionalarea asymmetry will often lead to differences in media volume asymmetry,but this is not always the case because cross sectional areas can bevaried along the length of the pleat so as to have a cumulative effectthat the total volume on each side of the media is equal.

The differences in cross sectional area are controlled by the geometryof the flute design. Often the presence, number, and shape of ridgesalong the flutes significantly impacts, and often determines, the amountof cross sectional area asymmetry. Flute geometry that results indifferences in cross sectional area can significantly impact flowproperties through the flutes. Changes in relative cross sectional areaof flutes typically results in changes in the cross sectional area ofthe upstream and downstream portion of the media pack in that area. Thepresent invention allows for customization of media volume asymmetry andcross-sectional area asymmetry to improve filter performance.

In some embodiments the media will have a cross-sectional area asymmetrysuch that one side of the media has cross sectional area at least 1percent greater than the opposite side the same piece of media. Oftenthe difference in cross-sectional area across the media will be morethan 3%, more than 5%, or more than 10%. Example media constructionsdemonstrate a media cross sectional area asymmetry of greater than 15%,greater than 20%, greater than 50%, greater than 75%, greater than 100%,greater than 150%, and greater than 200%. Suitable media cross sectionalarea asymmetry ranges includes, for example, 1% to 300%, 5% to 200%; 50%to 200%; 100% to 200%; and 100% to 150%.

Another aspect of some implementations of the invention involves thecord length (CL) of the media to determine media-cord percentage. Cordlength refers to the straight line distance from the center point of onepeak and the center point of an adjacent peak (see, for example,adjacent peaks 101, 102 of FIG. 5a ). In order to minimize the effect ofthe thickness of the media, the measurement for cord length isdetermined from a center point within the media. The media-cordpercentage can be determined according to the following formula:

${{media}\text{-}{cord}\mspace{14mu}{percentage}} = \frac{\left( {\left( {{1/2}\mspace{14mu} D\; 2} \right) - {CL}} \right) \times 100}{CL}$

By providing a single ridge or multiple ridges between adjacent peaks ofthe fluted media, the distance D2 can be increased relative to prior artmedia, resulting in increased media-cord percentage. As a result of thepresence of a ridge or a plurality of ridges, it is possible to providefiltration media having more media available for filtration comparedwith, for example, pleated media not having the ridges. This isparticularly valuable when combined with sharp flute peaks to reducemasking.

The measurement of media-cord percentage can be used to characterize theamount of media provided between adjacent peaks. In example embodimentsthe media-cord percentage is greater than 1%, alternatively greater than2%, 3%, 4%, or 5%. In some implementations media cord percentage isgreater than 7.5 percent, or greater than 10 percent. Suitable rangesfor media cord percentage include, for example, from 0.1% to 15%, from0.5% to 10%, and from 1% to 5%. The media cord-percentage will notalways be the same along the entire length of a flute, thus in someimplementations of the invention, at least 25% of the flutes exhibit amedia-cord percentage of at least 1% along 50% of the flute length. Inalternative implementations at least 25% of the flutes exhibit amedia-cord percentage of at least 2%, 3%, 4% or 5% along 50% of theflute length.

As noted above, the flute peaks are typically characterized by a sharpradius or a defined tip that reduces masking between pleats. Thisdefined tip can extend from the general profile of the flute to create aprotrusion at the flute peak that substantially reduces masking ofadjacent media. While it will be understood that a given flute peak willhave some variation in shape, and not necessarily form a perfect arc, itis still possible in some implementations to identify and measure adistance that corresponds substantially to a radius at the flute peak.This radius is measured on the interior of the flute and is calculatedas the effective inner radius. This effective inner radius can bemeasured in accordance with the disclosure provided below, and willgenerally be less than 4 millimeters, more often be less than 2millimeters, frequently be less than 1 millimeter, and optionally lessthan 0.5 mm. Larger radii can also be used in some implementations,especially for large flutes. It will further be understood that flutesthat fail to have a distinct or measurable radius still fall within thescope of the disclosure when they contain other characteristicsdescribed herein, such as the presence of ridges, media asymmetricvolumes, etc.

The pleated filtration media pack can be used to filter a fluid that canbe a gaseous or liquid substance. An exemplary gaseous substance thatcan be filtered using the filtration media is air, and exemplary liquidsubstances that can be filtered using the filtration media includewater, oil, fuel, and hydraulic fluid. The filtration media pack can beused to separate or remove at least a portion of a component from afluid to be filtered. The component can be a contaminant or anothermaterial targeted for removal or separation. Exemplary contaminants andmaterials targeted for removal include those characterized as solids,liquids, gases, or combinations thereof. The contaminants or materialstargeted for removal can include particulates, non-particulates, or amixture thereof. Materials targeted for removal can include chemicalspecies that can be captured by the media. The reference to removal ofcomponents and contaminants should be understood to refer to thecomplete removal or separation or a partial removal or separation.

Filter elements are also provided according to the invention, the filterelements incorporating media having flutes. Filter elements are providedthat can include a pleated filtration media pack and a seal arrangedrelative to the filtration media pack so that fluid to be filteredpasses through the filtration media pack as a result of entering inthrough one face of the media pack and out the other face of the mediapack. The seal can be attached directly to the pleated filtration mediapack or indirectly via a seal support, and can be provided to engage ahousing to provide a seal between the housing and the filter element.The seal can be provided as an axial seal, a radial seal, or acombination axial and radial seal. Crimp seals, pinch seals, and manyother forms of seals are also possible.

A method of filtering a fluid is also provided according to theinvention. The method includes a step of passing a fluid through apleated filtration media pack provided as part of a filter element as aresult of unfiltered fluid entering the first face or the second face ofthe pleated filtration media pack and out the other of the first face ofthe second face of the pleated filtration media pack. The flow of thefluid through the pleated filtration media pack can be characterized asstraight through flow.

The above summary of the present invention is not intended to describeeach disclosed embodiment of the present invention. This is the purposeof the detailed description and claims that follows.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention may be more completely understood in consideration of thefollowing detailed description of various embodiments of the inventionin connection with the accompanying drawings, in which:

FIG. 1 is a perspective view of a prior art pleated filtration mediapack.

FIG. 2 is a partial, sectional, perspective view of a portion of theprior art pleated filtration media pack of FIG. 1.

FIG. 3 is an enlarged, schematic, cross-sectional view of a portion ofthe prior art filtration media of the media pack of FIG. 1.

FIGS. 4a-c are enlarged, schematic, cross-sectional views of filtrationmedia according to the principles of the invention.

FIGS. 5a-d are enlarged, schematic, cross-sectional views of filtrationmedia according to the principles of the invention.

FIG. 6 is a perspective end view of a portion of a pleated filtrationmedia pack according to the principles of the invention.

FIG. 7 is an opposite perspective view of a portion of the filtrationmedia pack of FIG. 6.

FIG. 8 is a top, plan sectional view of the filtration media pack ofFIG. 7.

FIG. 9 is an enlarged, schematic, cross-sectional view of filtrationmedia according to the principles of the invention.

FIG. 10a is an enlarged, schematic, cross-sectional view of a portion ofa filtration media pack containing filtration media according to FIG. 9.

FIG. 10b is an enlarged, schematic, cross-sectional view of a portion ofa filtration media pack containing filtration media according to FIG. 9.

FIG. 11a is an enlarged, schematic cross-sectional view of a portion ofa filtration media pack according to principles of the invention.

FIG. 11b is an enlarged scanned cross-sectional image of a portion of afiltration media pack manufactured according to principles of theinvention.

FIG. 12 is a perspective view of a first face of a pleated, panelfiltration media pack according to the principles of the invention.

FIG. 13 is a perspective view of a second face of the pleated, panelfiltration media pack of FIG. 12.

FIG. 14 is a perspective view of a portion of the filtration media packof FIG. 12 showing the flow of fluid through the filtration media pack.

FIG. 15A is a perspective view of a first face of pleated, panelfiltration media pack according to the principles of the invention.

FIG. 15B is a perspective view of a second face of the pleated, panelfiltration media pack of FIG. 15A.

FIG. 16a is an enlarged scanned cross-sectional image of a fluteaccording to principles of the invention, showing a method to measurethe effective inner radius of a flute.

FIG. 16b is an enlarged scanned cross-sectional image of a portion of afiltration media pack according to principles of the invention, showinga method to measure the effective inner radius of a flute.

FIG. 17 is a perspective view of a portion of a cylindrical filtrationmedia pack according to the principles of the invention.

FIG. 18 is a perspective view of a portion of the cylindrical filtrationmedia pack according to FIG. 17 and showing flow of fluid through thefiltration media pack.

FIG. 19 is a schematic, perspective view of one type of a panel filterelement.

FIG. 20 is a schematic, perspective view of one type of a cylindricalfilter element, with a portion broken away.

FIG. 21 is a side elevation view of the filter element of FIG. 20, witha portion broken away.

FIG. 22 is a schematic side elevation view of one type of a conicalfilter element.

FIG. 23 is a schematic, perspective view of one type of a partialconical or bowed panel filter element.

FIG. 24 is a sectional view of the filter element of FIG. 23 taken alonglines 24-24.

FIG. 25-28 are graphs showing the data reported in the examples.

FIG. 29 is a graph showing relative performance of various panelfilters.

These drawings are to be considered general representations of theinvention, and it will be appreciated that they are not drawn toencompass all embodiments of the invention, nor are they always drawn toscale. It will also be understood that media made in accordance with theinvention will generally exhibit variation.

While the invention is susceptible to various modifications andalternative forms, specifics thereof have been shown by way of exampleand drawings, and will be described in detail. It should be understood,however, that the invention is not limited to the particular embodimentsdescribed. On the contrary, the intention is to cover modifications,equivalents, and alternatives falling within the spirit and scope of theinvention.

DETAILED DESCRIPTION

Pleated filtration media, pleated filtration media packs, filterelements containing pleated filtration media packs, and methods offiltering fluid are provided.

The phrase “pleated filtration media pack” refers to a media packconstructed or formed by folding, pleating, or otherwise formingfiltration media into a three-dimensional network. A pleated filtrationmedia pack can be referred to, more simply, as a media pack. Pleatedfiltration media packs can optionally be combined with other featuresfound in filter elements including a seal and a seal support. Ingeneral, a pleated filtration media pack includes filtration mediahaving a first set of pleat folds forming a first face, a second set ofpleat folds forming a second face, and the filtration media extendingbetween the first set of pleat folds and the second set of pleat foldsin a back and forth arrangement. It will be understood that in certainembodiments the “face” described herein can be substantially uneven orirregular, and can be planer or non-planer.

The pleat folds are generally formed as a result of folding or pleatingthe filtration media. The folds are typically formed transverse to themachine direction of the media, but that is not a requirement. The foldscan be formed at an angle that is different than an angle transverse tothe machine direction. The machine direction of the media generallyrefers to the continuous direction of the media.

In example embodiments the pleated filtration media pack includes afirst face formed as a result of a first set of pleat folds and a secondface formed as a result of a second set of pleat folds, and flutes thatextend directionally from the first face to the second face (or from thesecond face to the first face). The flutes are three dimensionalstructures formed in the filtration media that provide advantageous flowpaths along the pleat surfaces, allow for advantageous flow of fluidsthrough the media, and provide for efficient contaminant removal. Thus,the pleated media containing flutes is structured so as to provideimproved filtration performance under certain conditions.

The first face is generally the inlet or outlet of the pleatedfiltration media, and the second face is the other of the inlet oroutlet of the filtration media. For example, unfiltered fluid can enterthe pleated filtration media pack via the first face, and filtered fluidcan exit the pleated filtration media pack via the second face, or viceversa.

Flutes extending directionally from the first face to the second face,or directionally from the second face to the first face, of thefiltration media generally refers to a direction that is not parallel tothe first face or the second face. In many implementations the flutesextending directionally between the faces of the pleated media will bealigned perpendicular to the first or second face, or nearlyperpendicular to the first or second face.

It may be advantageous to have the flutes extending at anon-perpendicular angle relative to the first flow face or the secondflow face depending upon whether the fluid is flowing toward the firstface or the second face at an angle that is non-perpendicular. Byproviding the flutes at a non-perpendicular angle relative to the firstface or the second face of the pleated filtration media pack, it ispossible to enhance the flow of the fluid into the pleated filtrationmedia pack by adjusting the flute angle to better receive the fluid flowwithout the fluid having to make a turn before entering the pleatedfiltration media pack. The first face and the second face of the mediapack can be parallel or non-parallel. The angle at which the flutesextend can be measured relative to the first face, the second face, orboth the first face and the second face.

Thus, the flutes can be formed so that they extend perpendicular to thefirst face or the second face, or can be provided extending at an anglerelative to the first face or the second face that is greater than 0degrees but less than 180 degrees. If the flutes extend at an angle of 0degrees or 180 degrees to a face, then it is difficult for fluid toenter the pleated filtration media pack via the flutes. In general, itis desirable for the fluid to enter the pleated filtration media pack byentering through the flutes.

In some implementations the flutes will extend from about 85 degrees to95 degrees to a face, in other implementations from about 60 to 150degrees to a face, and in yet other implementations from about 70 to 110degrees to a face. Preferably, the flutes are provided extending at anangle that is within about 60 degrees of perpendicular to the first faceor the second face. In general, this range corresponds to about 30degrees to about 150 degrees relative to the first face or the secondface. Furthermore, the flutes can be provided extending within about 5degrees of perpendicular to the first face or the second face(corresponding to about 85 degrees to about 95 degrees relative to thefirst face or the second face). The flutes can desirably be providedextending perpendicular (90 degrees) relative to the first face or thesecond face.

During media formation, the limited dimension of the media is typicallythe width of the media because the machine on which the media ismanufactured is limited in the width direction. The length of the mediacan be continuous until it is cut or until it ends. The continuousdirection refers to the direction of the media along the length of themedia. The transverse direction generally refers to the direction of themedia across the width of the media. Pleated media generally includespleats or folds formed transversely to the machine direction so that thenumber of pleats can be controlled, as desired. Pleats or folds aretypically formed in the transverse direction such that the media foldsback upon itself in an alternating fashion (e.g., a back and fortharrangement) to form a filter element having a first face, a secondface, and an extension of media between the first face and the secondface. In general, fluid to be filtered enters one of the first face andthe second face of the filtration media pack, and exits the other of thefirst face and the second face.

Fluted media can be prepared by any technique that provides the desiredflute shapes. Thus, the invention is not limited to specific methods offorming the flutes. However, depending upon the flute geometry and themedia being fluted and pleated, certain methods will be more or lesssuccessful. Dry media with high cellulose content is relativelynon-stretchable, and is subject to tearing if it is stretched beyondjust a few percent. In contrast, media with a high synthetic content isoften much more stretchable. Both types of media are suitable for usewith the invention. Corrugation rollers can be used for forming fluteshaving a particular size and shape, generally relatively short and wideflutes. Media that is corrugated refers to media having a flutestructure resulting from passing the media between two flute rollers,e.g., into a nip or bite between two rollers, each of which has surfacefeatures appropriate to create a flute in the resulting media.

When it is desirable to increase the height of the flutes, it may bedesirable to use a method that essentially folds or pleats the media toform the flutes. In general, forming flutes by pleating (e.g., folding)can be referred to as micropleating because these pleats are far smallerthan the larger pleats or folds that form the faces of the media pack.Thus, such micropleating methods to form flutes should not be confusedwith pleating or folding to form the pleat folds that result in thefirst and second faces of the pleated filtration media pack. An exampletechnique for folding the media by micropleating to form flutes includesscoring and using pressure to create the fold. Accordingly, thefiltration media can be micropleated to form the flutes, andsubsequently pleated to form the pleated filtration media pack having afirst face and a second face.

Referring to FIGS. 1-3, a generalized pleated filtration media packaccording to the prior art is shown at reference number 10 of FIG. 1.The pleated filtration media pack 10 can be characterized as a pleatedfiltration media pack according to International Publication No. WO2005/082484. The pleated filtration media pack 10 of FIG. 1 is providedas a three-dimension network 11 resulting from pleating the media 12(see FIG. 2) to provide a first series of folds 14 forming a first face15 and a second series of folds 16 forming a second face 17.

In general, the media is folded back upon itself (in a back and fortharrangement) to provide both the first series of folds 14 and the secondseries of folds 16. Extensions of media 18 are provided between thefirst series of folds 14 and the second series of folds 16. During use,the sides 20 and 22 can be sealed so that fluid flowing into one of thefirst face 15 or the second face 17 flows out the other of the firstface 15 or the second face 17 or is otherwise filtered as a result ofpassing through the media before it leaves the filter element. The sides21 and 23 (e.g., top and bottom) can also be sealed, if desired.

Although FIG. 1 shows the first face 15, the second face 17 lookssimilar to the first face 15 (except that media with asymmetric flutecross sectional areas will have distinct first and second faces 15, 17).In general, the first series of folds 14 and the second series of folds16 can be referred to as pleat folds, and the first series of folds 14and the second series of folds 16 can look about the same. Extendingbetween the pleat folds 14 and 16 are extensions of media 18. Fluidflowing toward the first face 15 generally enters between opposed mediasurfaces 24 and 26. The area between the media surfaces 24 and 26 can becharacterized as openings 25. The fluid then passes through the media 12and exits out a downstream opening 29 between the media surfaces 28 and30 (as shown in FIG. 2) and out the second face 17. The area between themedia surfaces 28 and 30 can be referred to as the downstream opening29.

The openings 25 and 29 are both shown in FIG. 2 which is an illustrationof a portion of the pleated filtration media 12 without the pleat folds.It will be understood that FIGS. 1 to 3 shows generalized or stylizedpleat folds 14, 16 without showing the actual shape of the pleat folds.Also, it will be understood that not all media surfaces 24, 26, 28, 30are labeled, nor are all openings 25 and 29 labeled, but rather onlyexamples of such surfaces and openings have been labeled.

It should be understood that the reference numbers 24 and 26 willcorrespond to one side of the media 12, such as the upstream side or thedownstream side (wherein media surface 24 refers to the top surface, andmedia surface 26 refers to the bottom surface, as shown in FIG. 2).Similarly, reference numbers 28 and 30 refer to the other side of themedia 12, such as the downstream side or the upstream side (whereinpleat surface or media surface 28 refers to the top surface, and mediasurface 30 refers to the bottom surface, as shown in FIG. 2). As themedia 12 is pleated, one side of the media forms the upstream side andthe other side of the media forms the downstream side. For example,reference numbers 24 and 26 might refer to the upstream side of themedia, while reference numbers 28 and 30 refer to the downstream side ofthe media. Even though reference numbers 24 and 26 refer to differentmedia surfaces, they are both either on the upstream or downstream sideof the media. Similarly, even though reference numbers 28 and 30 referto different media surfaces, they are both either on the upstream ordownstream side of the media. While it is expected that most of thefluid flows between the media surfaces before being filtered, it isexpected that some of the fluid may flow through the pleat folds.

Now referring further to FIG. 3, the media 12 is illustrated in asectional view showing the raised area 34 delineating a repeating arc.In the context of the media 12, certain measurements can be taken tocharacterize repeating arcs 34. For example, the distance D1 defines thedistance underneath a raised area defined by the repeating arcs 34. Thedistance D1 can be taken as the distance between the center points 36and 38 of the media 12 of the same side arc peaks 40 and 42.

The distance D2 defines the media surface length for the raised area 34over the same distance D1 between the center points 36 and 38 of themedia 12 of the same side peaks 40 and 42. The distance J defines theheight measured from the lowest point to the highest point of the media12, and takes into account the thickness T of the media 12. The distanceJ is measured from the lowest point 44 of the peak 40 to the highestpoint 46 of an adjacent opposite side peak 48 perpendicular to the linedefining D1.

The generalized pleated filtration media pack of FIGS. 1 to 3 can becharacterized as having a symmetric media volume arrangement so that avolume on one side of the media pack is about the same as the volume onthe other side of the media pack. This symmetric volume is typical ofcurrent production filter media. In general, a symmetric volumearrangement is illustrated in FIG. 2, wherein the cross-sectional areaof the openings 25 are equal to the cross sectional area of the openings29. As a result of a symmetric volume arrangement, one face of the mediapack can look about the same as the other face of the media pack.

In order to enhance filter life, one technique is to increase the amountof filtration media in a pleated filtration media pack. In order toincrease the amount of media in pleated media, one technique is toincrease the number of pleats per given volume. As the number of pleatsper given volume increases, the pleat sides come closer and closer toone another. Especially under the pressure of fluid flow, adjacentpleats tend to contact one another and thereby restrict fluid flow therebetween. This type of restriction decreases filter performance.

While the media 12 of FIGS. 1-3 provides for some separation of themedia surfaces to allow fluid to enter and exit the pleated filtrationmedia via the first face 15 and the second face 17, the media 12 suffersfrom masking as a result of the contact between the media surfaces 24and 26 and/or the media surfaces 28 and 30. In general, masking is oftencharacterized by the location in the media where there is proximity toanother media sheet so that there is a resistance to flow through themedia at that location. As a result, masked media is of limitedusefulness for filtration, and masked media can be considered aneffective loss of media. For the media 12 shown in FIG. 3, the peaks 40,42, and 48 (for example) are relatively rounded, and as the mediasurfaces 24 and 26 and the media surfaces 28 and 30 touch, the areas ofcontact and those areas in sufficient proximity to the areas of contacttend to suffer from masking and do not contribute to media surface areaavailable for filtration.

While the particular area subject to masking along a given flute may berelatively small, the total amount of masked media over an entire filterelement can be substantial. It is possible to reduce the amount ofmasked media in a filter element while simultaneously modifying flutegeometry to increase the amount of media available for filtration. Byreducing masking, the performance or life of the filter element can beincreased, or the size of the filter element can be reduced whilemaintaining the same performance or filter life. In general, enhancingthe filter element life for a given filter element size or reducing thefilter element size for a given filter element performance can bereferred to as enhancing the filtration media performance.

Referring now to FIGS. 4a-c and 5a-d , various flute designs made inaccordance with the invention are described, the flute designs providedto decrease masking and thereby enhance filtration media performance. Ingeneral, FIGS. 4a-c and 5a-d are schematic representations of exampleflute designs for filtration media that can be utilized to provide peaksconfigured to decrease masking.

By providing a relatively sharp peak, the area of contact between facesheets is reduced as a result of providing sharper potential contactpoints between media surfaces. It is expected that during filtration,the filtration media will deflect under pressure. By providing arelatively sharp peak, a smaller amount of media will mask as a resultof deflection compared with less sharp peak during filtration.

Exemplary techniques for providing fluted media exhibiting relativelysharp peaks include bending, folding, or creasing the fluted media in amanner sufficient to provide a relatively sharp edge. The ability toprovide a relatively sharp peak depends on a number of factors,including the composition of the media itself and the processingequipment used for providing the bend, fold, or crease. In general, theability to provide a relatively sharp peak depends on the rupturestrength and thickness of the media and whether the media containsfibers that stretch or resist tearing or cutting. It is desirable toavoid tearing, cutting, or otherwise damaging the filtration mediaduring flute forming.

In FIGS. 4a-c exemplary cross-sectional views of fluted media 50, 60,and 70 are provided. The media 50, 60, and 70 include flutes 52, 62, and72 that can be referred to as truss shaped. In general, D1 is the flutewidth. The flute width D1 for media 50 is characterized as the distancebetween the same side peaks 54 and 56. For the media 60, the flute widthD1 is characterized as the distance between the same side peaks 64 and66. For the media 70, the flute width D1 is the distance between sameside peaks 74 and 76. The flute width D1 is measured from the centerpoints across the thickness of the media 50, 60, and 70. The value D2 isthe media length over the flute width measured from the same points asthe value for D1.

The flute height J is measured as the elevation distance between theouter most points of adjacent peaks perpendicular to the line definingD1 for a given flute. For example, the flute height J for media 50 ismeasured from the outer most point of the peak 56 to the outer mostpoint of the peak 58. The flute height J for media 60 is measured fromthe outer most point of the peak 66 to the outer most point peak 68. Theflute height J for media 70 is measured from the outer most point of thepeak 76 to the outer most point peak 78. For the media 50, the peaks 54,56, 57, and 58 can be characterized as having a relatively sharp peak.Similarly, for media 60 and 70, the peaks 64, 66, 67, 68, 74, 76, 77,and 78 can be characterized as having a relatively sharp peak. While theopposing peaks for media 50, 60, and 70 can be characterized as beingrelatively sharp, it is not necessary for all the peaks to be relativelysharp to benefit from reduced masking. For example, reduced masking canbe achieved by providing relatively sharp peaks on some or all flutes ononly one side of the media.

For example, media 50 in FIG. 4a can be characterized as having a seriesof first peaks 51 and a series of opposite second peaks 53. The firstpeaks 51 or the second peak 53 can be relatively sharp to providereduced masking benefits. Similarly, media 60 includes a first series ofpeaks 61 and second series of opposite peaks 63, and the media 70includes a first series of peaks 71 and a second series of oppositepeaks 73. In order to provide decreased masking, the media 60 and 70 canhave a relatively sharp first set of peaks 61 and 71, at the second setof peaks 63 and 73, or at both. Preferably, reduced masking is achievedby providing a sharp peak at both the first set of peaks 51, 61, and 71and the second set of peaks 53, 63, and 73.

Now referring to FIGS. 5a-c , cross-sectional views of fluted mediasheets 100, 120, and 140 are provided. It will be noted that FIGS. 5a-care not intended to be scale drawings of all acceptable flutegeometries, but rather merely show example implementations. In FIG. 5a ,the flute width D1 is measured from the center point of the peak 102 tothe center point of the peak 104. Alternatively, the flute width D1 canbe measured from the center point of the peak 101 to the center point ofthe peak 103.

The fluted media 100 is shown having two ridges 108 for each flute widthD1, or along the media length D2. The ridges 108 extend along at least aportion of the length of the flute. In general, each ridge 108 can becharacterized as a general area where a relatively flatter portion ofthe fluted media 108 a joins a relatively steeper portion of the flutedmedia 108 b. The use of the term “ridge” is intended to characterize aportion of the media that is not considered a peak. That is, ridges canbe provided between peaks, and ridges can be considered non-peaks. Aridge can be considered a line of intersection between differentlysloped media portions. It is important to note that in someimplementations the appearance of the ridge will be somewhat obscured byirregularities in the media itself. A ridge can be formed as a result ofdeformation of the media at that location. The media can be deformed atthe ridge as a result of applying pressure to the media.

For the example fluted sheet 100, the relatively flatter portion of thefluted media 108 a can be seen in FIG. 5a as the portion of the flutedmedia extending between the peak 101 and the ridge 108. The relativelysteeper portion of the fluted media 108 b can be characterized as thatportion of the media extending from the peak 102 to the ridge 108. Theridge can be formed as a result of creasing, bending, folding, coiningor otherwise manipulating the medial along a length of the fluted sheetduring the formation of the fluted media. It may be desirable, but it isnot necessary, during the step of forming the fluted media to take stepsto set the ridge. For example, the ridge can be set by heat treatment ormoisture treatment or a combination thereof. In addition, the ridge canexist as a result of creasing, bending, or folding without an additionalstep of setting the ridge.

The characterization of a ridge is not to be confused with the flutepeaks. The characterization of a generally flatter portion 108 a and agenerally steeper portion 108 b is intended as a way to characterize thepresence of a ridge 108. In general, the flatter portion 108 a and thesteeper portion 108 b may exhibit some curve. That is, it is expectedthat the flatter portion 108 a and the steeper portion 108 b will not becompletely planar, particularly as fluids such as air or liquid flowsthrough the media during filtration.

The presence of the ridge 108 of the media shown in FIG. 5a helpsprovide for reduced masking at the peaks 101 and 102. The ridge 108exists as a result of the forming the fluted sheet 100 and, as a result,reduces the internal stress on the media at the peaks. Without thepresence of the ridge 108, there would likely exist an increased levelof internal tension in the fluted sheet 100 that would cause the flutedsheet to create a greater radius at the peaks. The presence of the ridge108 helps increase the amount of media present between adjacent peaks(e.g., peaks 101 and 104) and helps sharpen the peaks 104 as a result ofrelieving, to a certain extent, the tension within the fluted sheet 100that would cause it to expand or flatten out at the peaks in the absenceof the ridge.

The presence of a ridge 108 can be detected by visual observation. Whilethe presence of the ridge may not be particularly apparent from viewingthe end of a flute, one can cut into the filter element and see thepresence of a ridge extending along a length of a flute. Furthermore,the presence of a ridge can be confirmed by a technique where the filterelement is loaded with dust, and the fluted sheet can be peeled away toreveal a cake of dust having a ridge corresponding to the ridge on thefluted media. The intersection of the two portions of the dust surfacecake forms a ridge. In an example implementation, the dust that can beused to load the media to fill the flutes to provide a cake of dustwithin the flutes can be characterized as ISO Fine test dust.

Although the fluted sheet 100 can be provided having two ridges 108along each length D2, the fluted sheet 100 can be provided having asingle ridge along each period length D2, if desired, and can beprovided having a configuration where some of the flutes exhibit atleast one ridge, some flutes exhibit two ridges, and some flutes exhibitno ridge, or any combination thereof.

Referring again to FIG. 5a , the fluted sheet 100 includes two ridges108 over the distance D2 where the distance D2 refers to the length ofthe fluted sheet 100 from the center point of the peak 102 to the centerpoint of the peak 104, and wherein the ridges are not the peaks. Flutepeaks 101 and 103 can be referred to as adjacent first side peaks, andthe peaks 102 and 104 can be referred to as adjacent second side peaks.Of course, the characterization of certain peaks as first side peaks andother peaks as second side peaks is arbitrary, and can be reversed, ifdesired.

The peaks can simply be referred to as peaks, as same side peaks, asadjacent first side peaks, or as adjacent second side peaks. In general,the reference to “adjacent same side peaks” refers to peaks that can beused to define a period. The reference to “adjacent peaks” without thecharacterization of “same side” refers to peaks next to each other butfacing in different directions. Adjacent peaks can be used to describeflute height. This characterization of the peaks is convenient fordescribing fluted media such as the media shown in the figures.

The fluted sheet can be characterized as having a repeating pattern offlutes when made by a process that repeats the flute pattern. Arepeating pattern of flutes means that across the width of the media(e.g., in the transverse direction), the pattern of flutes repeats. Forexample, every flute may exhibit a ridge between adjacent peaks.

There may be a pattern where every flute may exhibit two ridges betweenadjacent peaks. Furthermore, there may be a pattern where a ridge ispresent between adjacent peaks of some flutes but not between adjacentpeaks of other flutes. For example, a period may exhibit a single ridgeor two ridges, and a subsequent period may exhibit no ridge, a single,or two ridges, and a subsequent flute may exhibit no ridge, one ridge,or two ridge, etc. At some point, the pattern typically repeats itself.In some such periods there may be three or more ridges.

The characterization of the presence of a ridge should be understood tomean that the ridge is present along a length of the flute. In general,the ridge can be provided along the flute for a length sufficient toprovide the resulting media with the desired performance. While theridge may extend the entire length of the flute, it is possible that theridge will not extend the entire length of the flute (100% of the flutelength) as a result of, for example, influences at the ends of the flutesuch as pleating or folding.

Preferably, the ridge extends at least 10% of the flute length, moretypically 25% of the flute length. By way of example, the ridge canextend at least 30% of the flute length, at least 40% of the flutelength, at least 50% of the flute length, at least 60% of the flutelength, or at least 80% of the flute length. Such ridges can extend in acontinuous or discontinuous fashion along the length of the flutes.Also, the ridges can be uniformly distributed along flutes, or can benon-uniformly positioned along the length of the flutes. For example, incertain embodiments in may be desirable to have the flutes distributedsuch that they have more or fewer ridges near either the upstream ordownstream face of a media pack.

There is no requirement, however, that a ridge or two ridges are presentbetween every adjacent peak, or that there is a repeating pattern.Benefits of the invention can be obtained by providing flutes, whereinat least some of the flute exhibit at least one ridge between adjacentpeaks. In some implementations, at least 25% of the flutes exhibit atleast one ridge between adjacent peaks in order to achieve the benefitsof the presence of the ridge. Even more preferably, at least 50% of theflutes, and more preferably 100% of the flutes, exhibit at least oneridge between each adjacent peak of the flute.

Referring to FIG. 5b , the fluted media 120 includes two ridges 128 and129 between adjacent peaks 124 and 125. Along the length D2, the media120 includes four ridges 128 and 129. A single period length of themedia includes four ridges in the depicted embodiment. It should beunderstood that the ridges 128 and 129 are not the peaks 124, 125, or126. The media 120 can be provided so that between adjacent peaks (e.g.,peaks 125 and 126) there are two ridges 128 and 129. Again, a patterncan be provided. In the pattern shown in FIG. 5b , there are two ridgesbetween each adjacent peak, and there are four ridges provided in eachperiod. In an alternative repeating pattern, there may be any number(for example, 0, 1, 2, or more) ridges between adjacent peaks as long asthe pattern includes the occurrence of at least one ridge betweenadjacent peaks somewhere in the pattern. In a desired embodiment shownin FIG. 5b , there are two ridges between each adjacent peak. The ridge128 can be characterized as the area where a relatively flatter portionof the media 128 a joins a relatively steeper portion of the flutedmedia 128 b.

The ridge 129 can be provided as a result of the intersection of therelatively flatter portion of the fluted media 129 a and the relativelysteeper portion of the fluted media 129 b. The relatively steeperportion of the fluted media 129 b can be characterized as that portionof the fluted media extending between the ridge 129 and the peak 125 andcan be characterized (for example) as having an angle between the ridge129 and the peak 125. Peak 125 extends above the flatter portions of thefluted media 129 a. Thus, the peak 125 shows a defined protrusion fromthe adjacent flute media 129 a.

Now referring to FIG. 5c , the fluted media 140 includes at least tworidges 148 and 149 between the adjacent peaks 144 and 145. Along thelength D2, the media 140 includes four ridges 148 and 149. A singleperiod length of media can include four ridges. It should be understoodthat the ridges 148 and 149 are not the peaks 144, 145, and 146. Themedia 140 can be provided so that between adjacent peaks (e.g., peaks144 and 145) there are two ridges 148 and 149. In addition, the flutedsheet 140 can be provided so that between other adjacent peaks, there isone ridge, two ridges, or no ridge.

There is no requirement that between each adjacent peak there are tworidges. There can be an absence of ridges between peaks if it isdesirable to have the presence of ridges alternate or provided atintervals between adjacent peaks. In general, a pattern of flutes can beprovided where the pattern of flutes repeats and includes the presenceof ridges between adjacent peaks.

The ridges 148 and 149 can be characterized as the areas where arelatively flatter portion of the fluted sheet joins a relativelysteeper portion of the fluted sheet. In the case of the ridge 148, arelatively flatter portion of the fluted sheet 148 a joins a relativelysteeper portion of the fluted sheet 148 b. In the case of the ridge 149,a relatively flatter portion of the fluted sheet 149 a joins arelatively steeper portion of the fluted sheet 149 b. The fluted media140 thus has sharp peak peaks 145 and 146.

The fluted sheets 110, 120, and 140 are shown as relatively symmetricalfrom peak to peak. That is, for the media 110, 120, and 140, the flutesrepeat having the same number of ridges between adjacent peaks. Adjacentpeaks refer to the peaks next to each other along a length of flutedmedia. For example, for the fluted media 110, peaks 101 and 102 areconsidered adjacent peaks, and peaks 102 and 104 can be consideredadjacent same side peaks. A period of media, however, need not have thesame number of ridges between adjacent peaks, and the media can becharacterized as asymmetrical in this manner. That is, the media can beprepared having a ridge on one half of the period and not having a ridgeon the other half of the period.

Another advantage to providing for the presence of the ridges (e.g.,108, 128, 129, 148 and 149) is that these ridges help reduce stress onthe media to provide a sharper peaks. In general, without the ridgesbeing formed, a greater amount of tension or memory in the media maycause the peaks to become wider, and thereby exhibit a greater level ofmasking. By introducing the ridges into the filtration media whenfluting the filtration media, it becomes easier to create and helpmaintain relatively sharp peaks to reduce masking.

Another technique for reducing masking, or for providing pleated mediawith a relatively low level of masking, while maintaining filtrationmedia area, is to decrease the potential number of contacts between thepleated faces for a given volume. In general, potential contacts referto the potential contacts between flute peaks on one media surface andthe corresponding flute peaks on an adjacent media surface. Onetechnique for doing this is to increase or decrease the flute widthheight ratio. The flute open channel width height ratio is the ratio ofthe flute period length D1 to the flute height J. The flute width heightratio can be expressed by the following formula:flute width height ratio=D1/JMeasured distances such as flute period length D1 and flute height J canbe characterized as average values for the filtration media along theflute length excluding 20% of the flute length at each end (due todistortions in the flutes as a result of forming the pleat folds). Thus,the distances D1 and J can be measured away from the ends of the flutesbecause the ends of the flutes are typically deformed as a result ofpleating. The flute width height ratio calculated at a pleat fold wouldlikely not represent the flute width height ratio of the flute away fromthe pleat fold. Accordingly, the measure of flute width height ratio canbe provided as an average value over the flute length with the exceptionof the last 20% of the flute length near the ends of the flutes. For“regular” media, such as, media having non-tapered flutes, it isexpected that the flute period length D1 and the flute height J can berelatively constant along the flute length. By relatively constant, itis meant that the flute width height ratio can vary within about 10%over the length of the flute excluding the 20% length at each end wherethe pleat folds may affect the width height ratio.

In the case of a “non-regular” media, such as, media having taperedflutes, the flute width height ratio can vary or remain about the sameover the length of the flute. Another example of non-regular mediaincludes media wherein at least a portion of the flutes have a fluteheight (J) that changes over the flute length. An advantage of providinga flute wherein the flute height or flute width varies over the lengthof the flute is the ability to reduce potential contact between adjacentmedia surfaces and thereby reduce masking.

Now referring to FIGS. 4a-c , the media 50, 60, and 70 show variousflute width height ratios. If considered as drawn to scale, the flutewidth height ratio of media 50 is about 2.5, the flute width heightratio of media 60 is about 5.8, and the flute width height ratio ofmedia 70 is about 0.34. In general, preferred flutes exhibit a widthheight ratio of about 1 to about 8, preferably about 1.5 to about 7.5,and more preferably about 2 to about 5. In order to enhance the life ofthe media pack, a flute width height ratio of greater than 2, greaterthan about 2.5, or greater than 3 is desirable. In some implementationsthe flute width height ratio is greater than 4.

Another property similar to flute width height ratio that can provide ameaningful way to understand the flutes is “open channel width heightratio.” In general, open channel width height ratio can be determinedaccording to the formula:open channel width height ratio=D1/CIn this formula, C is the open channel flute height which is the fluteheight (J) minus the media thickness (T). The open channel width heightratio is an advantageous property because it is not based upon the mediathickness. In the case of the media 50, 60, and 70 of FIGS. 4a-c , theopen channel width height ratios can be calculated as 2.82, 5.83, and0.36, respectively. In the case of truss shaped flutes, it is oftendesirable for the flutes to exhibit an open channel width height ratioof greater than 2. In order to enhance media performance, it isgenerally desirable to provide open channel width height ratio greaterthan about 2.25, greater than about 2.5, greater than about 2.75, orgreater than about 3. The open channel width height ratio is preferablyless than about 10, less than about 9.5, less than about 9, less thanabout 8.5, less than about 8, less than about 7.5, or less than 6. Inexample implementations the open channel width height ratio is from 2 to7, is from 3 to 6, or from 4 to 5.

In order to show the effect that media thickness has on the width heightratio and the open channel width height ratio, attention is directed toFIG. 5d . For the media 150 shown in FIG. 5d , the width height ratiocan be calculated to be 2.1, and the open channel width height ratio canbe calculated to be 2.75.

While reducing masking is desirable in order to enhance filtration mediaperformance, another technique to enhance filtration media performanceis to increase the amount of media area available for filtration in agiven volume. The media configurations shown in FIGS. 5a-c showtechniques for enhancing the amount of media surface area present in agiven volume. The media-cord percentage can help measure how a fluteconfiguration can provide a filtration media pack with enhanced mediasurface area in a given volume. The media-cord percentage requires ameasurement of the cord length (CL).

The relationship between the cord length CL and the media length D2 canbe characterized as a media-cord percentage. The media-cord percentagecan be determined according to the following formula:

${{media}\text{-}{cord}\mspace{14mu}{percentage}} = \frac{\left( {\left( {{1/2}\mspace{14mu} D\; 2} \right) - {CL}} \right) \times 100}{CL}$

By providing a single ridge or multiple ridges between adjacent peaks ofthe fluted media, the distance D2 can be increased relative to prior artmedia. As a result of the presence of a ridge or a plurality of ridges,it is possible to provide filtration media having more media availablefor filtration compared with, for example, pleated media not having theridges. The measurement of media-cord percentage can be used tocharacterize the amount of media provided between adjacent peaks. Thelength D2 is defined as the length of the fluted sheet 100, 120, and 140for a period of the fluted sheet 100, 120, and 140. In the case of thefluted sheet 100, the distance D2 is the length of the fluted sheet fromthe peak 102 to the peak 104. This distance includes two ridges 108. Inthe case of the fluted sheet 120, the length D2 is the distance of thefluted sheet 120 from the peak 124 to the peak 126. This distanceincludes four ridges 128 and 129. In the case of the fluted sheet 140,the length D2 is the distance of the fluted sheet 140 from the peak 144to the peak 146. This distance includes four ridges 148 and 149.

The existence of increased filtration media between adjacent peaks as aresult of providing one or more ridges between adjacent peaks can becharacterized by the media-cord percentage. By way of example, pleatedmedia according to the prior art (e.g., the media shown in FIG. 1-3)typically exhibits a media-cord percentage of about 0.09% to about0.89%. For the flutes made in accordance with the present invention, themedia-cord percentage can be greater than about 1%, greater than about1.5%, and greater than about 2%. In some implementations the media-cordpercentage is greater than 3%, and optionally greater than 4%. The mediacord percentage can exceed 5% in some implementations. The media-cordpercentage is generally less than about 25%, more typically less thanabout 20%.

Another technique for increasing the amount of filtration mediaavailable for filtration includes increasing the flute density of themedia pack. The flute density refers to the number of flutes percross-sectional area of filtration media in a filtration media pack. Theflute density depends on a number of factors including the flute heightJ, the flute period D1, and the media thickness T. The flute density canbe referred to as a media pack flute density, and is determined at pleatcount maximum (PCMax). PCMax is the maximum pleat count concentration atwhich the panel can be manufactured without deforming the flutes. Ingeneral, PCMax refers to the maximum number of pleats that can be placedin a given volume before performance suffers as a result of deformationof the flutes. This implies that in a panel configuration modeled, flutepeaks on adjacent media faces will touch along substantially theirentire length. For panel filters, PCMax pleat concentration is equal to1/(2J). The equation for calculating the media pack flute density (ρ)for a filter element is:

$\rho = {\frac{1}{2}\frac{{number}\mspace{14mu}{of}\mspace{14mu}{flutes}\mspace{14mu}\left( {{open}\mspace{14mu}{and}\mspace{14mu}{closed}} \right)}{{media}\mspace{14mu}{pack}\mspace{14mu}{cross}\mspace{14mu}{sectional}\mspace{14mu}{area}}}$

The flute density of a filter element can be calculated by counting thenumber of flutes including those flutes that are open and those flutesthat are closed in a cross sectional area of the filter element, anddividing that by two times the cross sectional area of the filterelement at the location where the number of flutes was determined. Ingeneral, for regular media it is expected that the flute density willremain relatively constant across the length of the filter element fromthe inlet face to the outlet face, or vice versa.

It should be understood that the media cross sectional area refers tothe cross sectional area of the media and not necessarily to the crosssectional area of the filter element. The filter element may have asheath or a seal intended to engage a housing that would provide thefilter element with a cross-sectional area that is greater than thecross-sectional area of the media. Furthermore, the cross-sectional areaof the media refers to the effective area of the media pack, and doesnot include portions of the media pack not useful for filtration (suchas areas obscured by the seal).

In general, providing a media pack having increased flute density has atendency to increase the surface area of media within a volume of themedia and, therefore, has a tendency to increase the loading capacity ofthe filtration media. Accordingly, increasing the flute density of mediacan have the effect of enhancing the loading capacity of the media.However, increasing the flute density of media can have the effect ofincreasing the pressure drop through the media assuming other factorsremain constant.

Increasing the flute density of filtration media can have the effect ofdecreasing the flute height (J) or the flute period length (D1), orboth. As a result, the size of the flute (the size of the flute refersto cross sectional area of the flute) tends to decrease as flute densityincreases. As a result, smaller flute sizes can have the effect ofincreasing the pressure drop across the filtration media pack. Thereference to a pressure drop across the media pack refers to thepressure differential determined at a first face of the media packrelative to the pressure measured at a second face of the media pack,wherein the first face and the second face are provided at generallyopposite side of the media pack. The pressure drop across the media packdepends, in part, on the flute density and the flute length.

The ratio D2/D1 can also be relied upon for demonstrating the presenceof more filtration media compared with, for example, pleated mediaaccording to FIGS. 1-3. In general, prior art pleated media according toFIGS. 1-3 can be considered to exhibit a D2/D1 ratio from 1.004 to1.035. A media pack according to the invention can be provided having aD2/D1 ratio greater than 1.04. For a filtration media pack wherein theflutes are provided having a truss shape, the ratio of D2/D1 can be 1.05to 1.35, and preferably 1.1 to 1.3. In some implementations the ratio ofD2/D1 can be from 1.05 to 1.50.

Now referring to FIGS. 6-8, a pleated filtration media pack where themedia has the flute shape shown in FIG. 5a is shown at reference number200. The pleated filtration media pack 200 includes media 202 having amachine direction 204 and a transverse direction 206. The media isfolded to provide a first series of pleat folds 208 and a second seriesof pleat folds 210 (see FIG. 8), wherein the media 202 extends in a backand forth arrangement between the first set of pleat folds 208 and asecond set of pleat folds 210. The media 202 includes flutes 220. Theflutes 220 include a relatively sharp peaks 222 and 224. In addition,the flutes 220 include ridges 226 provided between adjacent peaks (e.g.,peak 222 and 224).

The pleated filtration media pack 200 includes media surfaces 232 and234 that form openings 236 there between, and media surfaces 238 and 240that form openings 242 there between. The pleated filtration media pack200 can be characterized as having a first face 250 that includes thefirst set of pleat folds 208 and the openings 236. In addition, thepleated filtration media pack 200 can be characterized as having asecond face 252 that includes the second set of pleat folds 210 and theopenings 242. Accordingly, air can flow into the pleated filtrationmedia pack 200 via the openings 236 in the first face 250, pass throughthe media 202 to provide filtration, and then flow out of the pleatedfiltration media pack 200 via the openings 242 in the second face 252.In certain circumstances, it may be advantageous to have the fluid flowinto the pleated filtration media pack via the second face 252 and outof the pleated filtration media pack 200 via the first face 250.

There are a number of advantages resulting from the pleated filtrationmedia pack 200 compared with, for example, the pleated filtration mediapack according to FIGS. 1-3. For example, the pleated filtration mediapack 200 exhibits a desirable width height ratio that contributes tolimiting the number of potential contacts between media surfaces. Bylimiting or reducing the number of potential contacts between mediasurfaces, there exists the ability to reduce masking and thereby providefor the presence of more media available for filtration in a givenvolume. Furthermore, the pleated filtration media pack 200 provides aflute shape consistent with the flute shape shown in FIG. 5a . That is,the flute shape provides for the presence of ridges 226. By providingfor ridges 226, the flutes have relatively high media-cord percentages.By increasing the media-cord percentage, more media can be provided in agiven volume compared with, for example, the pleated filtration mediapack shown in FIGS. 1-3. Furthermore, by providing the pleatedfiltration media pack 200 with a flute shape consistent with the fluteshape shown in FIG. 5a , the peaks (or at least a portion of the peaks)can be relatively sharp. As a result of the relatively sharp radius,masking caused by contact between media surfaces can be reduced. Inaddition, the pleated filtration media pack 200 provides for mediavolume asymmetry (also referred to as media asymmetric volume) and mediacross-sectional area asymmetry.

It can be appreciated that the existence of media volume asymmetry ormedia area asymmetry represent a flute shape that deviates from thetruss shape shown in FIGS. 4a-c and the prior art pleated media shown inFIGS. 1-3. The flute shapes shown in FIGS. 5a-c are exemplary flutesthat can provide for media volume asymmetry and media area asymmetry.

Another advantage of the pleated filtration media pack 200 according toFIGS. 6-8 is that it can utilize media that can only handle a relativelysmall amount of strain because the pleat folds are formed to keepoverall media length relatively constant and reduce strain. In general,media that can tolerate only a relatively small amount of strainincludes media that has tendency to rupture when the strain is greaterthan as little as 3%, such as is often the case for media that has ahigh cellulose content and is cold and dry. Even wet, warm media willoften have a tendency to rupture when the strain is greater than about8% with some media, and about 10% in other media, or occasionallygreater than about 12%. Thus, the flute designs of the present inventioncan be used, in some implementations, with media that has high cellulosecontent. In some embodiments the cellulose content is at, or near, 100%.In other implementations the cellulose content is greater than 90%, 80%,70%, 60% or 50%.

As shown in FIG. 8, the machine direction distance between the first setof pleat folds 208 and the second set of pleat folds 210 is constantacross the transverse direction 206. This allows for a pleat foldconfiguration that results in an overall strain on the media that isrelatively small. Accordingly, the media that can be used in thefiltration media pack can be characterized as media not capable ofwithstanding strain of greater than about 8% in some implementations,10% in other implementations, or greater than about 12% in yet otherimplementations. However, it will be understood that media able towithstand high levels of strain can also be used with variousimplementations of the invention.

In general, media volume asymmetry refers to the volume asymmetrybetween an upstream side and a downstream side of a pleated filtrationmedia pack wherein the volume asymmetry is calculated based upon thevolume asymmetry caused by the media fluting arrangement rather than bythe packing arrangement within a media pack. Media cross-sectional areaasymmetry is calculated in a similar way except that it is based upon across-section of the media taken at a point along the length of a flute.

In order to further understand what is meant by the phrase, “mediavolume asymmetry,” reference is made to FIGS. 9-10 b. In the case ofFIG. 9, the media 250 is shown fluctuating between a first theoreticalplane 252 and a second theoretical plane 254. The media volume asymmetryrefers to the volume differential on one side of the media 250 comparedwith the other side of the media 250 between the theoretical planes 252and 254 for the media pack. One way to characterize the theoreticalplanes 252 and 254 is to consider that the media 250 is pleated andsufficiently packed so that the peaks 256 and 258 contact opposing mediasurfaces as shown in FIG. 10 a.

The media volume asymmetry is caused by the media fluting arrangementrather than by the packing arrangement within a media pack. An opencross-sectional area on one side of the media (FIG. 9, area 257) may beseen to be extending from one surface of the media, to a line defined byflute peaks on the same side of the media. This area is greater than anopen cross-sectional area on the other side of the media (FIG. 9, area259) bounded by the opposite surface of the media, and a line defined byopposing flute peaks. These cross-sectional areas define mediacross-sectional area asymmetry for a given cross-section of media.

Extending cross-sectional area asymmetry from the upstream face to thedownstream face of the pleat pack then characterizes upstream volumesand downstream volumes and in turn, media volume asymmetry. For a pleatpack, for cases where flute peaks do or do not extend from pleat fold topleat fold, where the media between pleat folds shows little curvatureand is substantially flat (where the centroids of sections of flutes inmedia between pleat folds substantially fall on a planar surface), theupstream media volume can be seen to be the volume enclosed by theupstream media surface, the contiguous surface at the pleat folds, and aconvex hull formed over the flute peaks to center line of the pleatfolds. The downstream media volume can be seen to be the volume enclosedby the downstream media surface, the contiguous surface at the pleatfolds, and a convex hull formed over the flute peaks to center line ofthe pleat folds. Media volume ratio is the ratio of this upstream mediavolume to the downstream media volume.

The pleat packing arrangement shown in FIG. 10a can be characterized aspleat count maximum (PCMax) since it represents the largest number ofpleats in a given volume wherein the flutes do not distort each other.In FIG. 10a , a sectional view of the media 250 is shown where the media250 is pleated back and forth upon itself. Based upon this calculationof media volume asymmetry, the value of media volume asymmetry for themedia arrangement shown in FIG. 10a is the same as the media volumeasymmetry for the media arrangement shown in FIG. 10b . In FIG. 10b ,the media 250 is pleated but the peaks 256 and 258 do not touch.Accordingly, the definition of media volume asymmetry takes into accountthe potential separation between media surfaces that may exist when amedia is pleated and formed into a pleated filtration media pack.

The theoretical planes 252 and 254 are determined based upon astatistical maximum peak value. Aberrations are discarded from thecalculation. For example, there may be an occasional peak that is eithertoo high or too low and that does not significantly affect the packingdensity of the filtration media. Those peaks are not considered forpurposes of calculating the theoretical planes 252 and 254. Furthermore,it should be understood that there may be occasions where peaks areskipped or formed at a height significantly below the average fluteheight in order to enhance volume asymmetry. In those cases, the reducedpleat height would not affect the packing density calculation. Ingeneral, the packing density refers to the number of pleats available ina given volume with just the peaks of media surfaces touching as shownin FIG. 10 a.

An advantage of calculating a “media volume asymmetry” is that thevolume of the media (the upstream volume and the downstream volume) canbe calculated based upon the media and the results can be different thanthe actual upstream and downstream volume of a filter element. Forexample, the media can be arranged as a panel where the peaksessentially just touch each other. In that case, the upstream volume anddownstream volume of a filter element should be consistent with the“media volume asymmetry” calculation.

Alternatively, however, the media can be arranged in a configurationwhere the peaks do not touch each other. For example, the media surfacescan be sufficiently separated from each other in a panel filter element,or can be separated from each other as is the typical case in acylindrical filter element. In those cases, the volume asymmetry in thefilter element is expected to be different from the “media volumeasymmetry” calculation. Accordingly, the use of the “media volumeasymmetry” calculation is a technique for normalizing the calculation ofvolume asymmetry (or volume symmetry) for a filtration media pack basedupon the media itself and irrespective of how the media is arranged orpacked in a filter element. Another calculation that can have value isthe actual volume asymmetry in a filter element. The actual volumeasymmetry for a filter element refers to the volume asymmetry resultingfrom a difference in volume between an upstream side of the element anda downstream side of the element. The arrangement of the media (e.g.,panel or cylinder) can affect this value.

Media cross-sectional area asymmetry can also be calculated byexamination of a filter element, but the cross-sectional area isdesirably measured away from the pleat folds. Thus, for example, themedia cross-sectional area can be taken along a flute length over adistance that excludes three times the flute height from the pleat fold.The reason that the media cross-sectional area asymmetry is calculatedaway from the pleat folds is to avoid the influence of the pleat foldson the media cross-sectional area asymmetry calculation. Furthermore, itshould be understood that the media cross-sectional area asymmetry mayvary along a flute length. This variation can be a result of a flutetaper.

With regard to media cross-sectional area asymmetry, the cross-sectionalarea of media will typically demonstrate asymmetry on each side of themedia. As shown in FIG. 10A, a cross section shows an asymmetry in crosssectional area 253 with cross sectional area 255.

The three dimensional structure of flutes defines an open volume forflow of fluid, as well as space for contaminants (such as dust) toaccumulate. In some embodiments the filtration media exhibits a mediavolume asymmetry such that a volume on one side of the media is greaterthan a volume on the other side of the media. In general, media volumeasymmetry refers to the volume asymmetry between an upstream side and adownstream side of pleated filtration media containing flutes. The mediavolume asymmetry is caused by the media fluting arrangement rather thanby the packing arrangement within a media pack.

Now referring to FIGS. 11A and 11B, a schematic cross-section view of aportion of a filtration media pack is shown in FIG. 11A, along with ascanned cross sectional image in FIG. 11B. In FIG. 11A, across-sectional view of the media 450 is shown where the media 450 ispleated back and forth upon itself. The peaks 456 and 458 touch in thedepicted embodiment. Each peak 456, 458 extends from the adjacentportions of the flute 460, 462. In the depicted embodiment, each flutecontains ridges 464, 468. It will be observed in FIG. 11B that the peaks456 and 458 comprise tips that extend beyond the general profile of thesurrounding flute. In the embodiment depicted, the general profile ofthe flute is characterized by the portions 460, 462, with the peak 462projecting upward from that general profile. It will be observed, forexample, that the prior art media of FIGS. 1 to 3 does not have peaksthat project above the adjacent media in the manner depicted in (forexample, and without limitation) FIGS. 5B, 11A, and 11B.

A cross sectional scanned photograph of media constructed in accordancewith the invention is shown in FIG. 11B, and it also shows across-sectional view of the media 450 pleated back and forth uponitself. The peaks 456 and 458 touch in the depicted embodiment. In thedepicted embodiment, each flute contains ridges 464, 468. It will beobserved from FIG. 11B that a media pack can show variability withoutdeviating from the scope of the invention. Thus, the media pack of FIG.11B shows an actual implementation of the media pack drawn in FIG. 11A.

Now referring to FIGS. 12-14, a filtration media pack is shown atreference number 300. The filtration media pack includes pleat folds 302that form a first face 304 (see FIG. 12), and pleat folds 306 that forma second face 308 (see FIG. 13). The media surfaces 310 and 312 areseparated from each other so that they do not touch, and the mediasurfaces 314 and 316 are separated from each other so they do not touch.Openings 320 are provided between media surfaces 310 and 312, andopenings 322 are provided between media surfaces 314 and 316. As shownin FIG. 14, fluid flow through an opening 320 in the first face 304passes through the media to provide filtration of the fluid and thenexists through another opening 322 in the second face 308.

A filter element or filter cartridge can be provided as a serviceablefilter element. The term “serviceable” in this context is meant to referto a filter element containing filtration media where the filter elementcan be periodically removed and replaced from a corresponding aircleaner. An air cleaner that includes a serviceable filter element orfilter cartridge is constructed to provide for the removal andreplacement of the filter element or filter cartridge. In general, theair cleaner can include a housing and an access cover wherein the accesscover provides for the removal of a spent filter element and theinsertion of a new or cleaned (reconditioned) filter element.

A pleated filtration media pack formed into a panel can be referred toas a “straight through flow configuration” or by variants thereof whenthe faces on the pleated filtration media are parallel. For example, afilter element provided in the form of a panel generally can have aninlet flow face and an exit flow face, with flow entering and exitingthe filter element in generally the same straight through direction. Insome instances, each of faces can be generally flat or planar, with thetwo parallel to one another. However, variations from this, for examplenon-planar faces, are possible in some applications.

Alternatively, the inlet and outlet flow faces can be provided at anangle relative to each other so that the faces are not parallel. Inaddition, a filter element can include a filtration media pack having anon-planar face, and a non-planar face can be considered non-parallel toanother face. An exemplary non-planar face for a filtration media packincludes a face that forms the interior surface or the exterior surfaceof a filtration media pack formed in a cylindrical arrangement or in aconical arrangement. Another exemplary non-planar face for a filtrationmedia pack includes a filtration media pack wherein the media surfaceshave an inconsistent or irregular pleat depth (e.g., the pleat depth ofone pleat is different from the pleat depth of another pleat). The inletflow face (sometimes referred to as “end”) can be referred to as eitherthe first face or the second face, and the outlet flow face (sometimesreferred to as “end”) can be referred to as the other of the first faceor the second face.

A straight through flow configuration found in filter elementscontaining pleated filtration media formed into a panel is, for example,in contrast to cylindrical filter elements containing pleated filtrationmedia arranged in a cylindrical configuration of the type shown in U.S.Pat. No. 6,039,778, in which the flow generally makes a substantial turnas its passes through the filter element. That is, in a filter elementaccording to U.S. Pat. No. 6,039,778, the flow enters the cylindricalfilter cartridge through a cylindrical side, and then turns to exitthrough a cylindrical filter end in a forward-flow system. In areverse-flow system, the flow enters the cylindrical filter cartridgethrough an end and then turns to exit through a side of the cylindricalfilter cartridge. An example of such a reverse-flow system is shown inU.S. Pat. No. 5,613,992. Another type of filter element containingpleated filtration media can be referred to as a conical filter elementbecause the filtration media pack is arranged in a conical form.

Now referring to FIGS. 15a and 15b , a pleated filtration media pack isshown at reference number 350 wherein the media surfaces 352 and 354 aretouching, and media surfaces 356 and 358 are touching. It will be notedthat the pleat folds of the filtration media pack 350 are depicted in ageneralized manner without showing the actual structure of the folds.More detailed depictions of the actual structure of the pleat folds isshown (by way of example), in such places as FIG. 14.

In general, the pleated filtration media pack 350 of FIG. 15a is shownin an example form where the pleat density is at a theoretical maximum(PCMax) where the peaks of the flutes on opposing pleats touch alongtheir entire depth. This maximizes the number of pleats in a givenvolume and thereby maximizes the amount of media in a given volume. Asillustrated in FIGS. 15a and 15b , the media surfaces 352 and 354 showopenings 360, and media surfaces 356 and 358 show openings 362 thatillustrate both a media volume asymmetry and a media cross-sectionalarea asymmetry. An advantage to providing volume asymmetry is that thegreater volume can be provided as the dirty side volume or as the cleanside, as desired. When the greater volume is provided on the dirty side,the filter element can have a longer life when provided as a panelfilter. The media on the dirty side volume or the upstream side isgenerally the portion of the media that becomes caked with particulates.By increasing the volume on the upstream side, such as by creatingvolume asymmetry, it is possible to enhance media pack performance byincreasing life.

As noted above, flute peaks are typically characterized by a sharpradius or a defined tip that reduces masking between pleats. While itwill be understood that flute peaks will have some variation in shape,and not necessarily form a perfect arc, it is still possible in someimplementations to identify and measure a distance that correspondssubstantially to a radius. This radius (local effective inner radius),which can be measured in accordance with the disclosure provided below,will generally be less than 4 millimeters, more often be less than 2millimeters, frequently be less than 1 millimeter, and optionally lessthan 0.5 mm. Larger radii can be suitable for large flutes. It willfurther be understood that flutes that fail to have a distinct ormeasurable radius still fall within the scope of the disclosure whenthey contain other characteristics described herein, such as thepresence of ridges, media asymmetric volumes, etc.

Example radius r of a prior art media is shown in FIG. 3. With regard tothe present invention, radius r is shown in FIGS. 4a, 4b, 4c, 5a, 5b,and 5c for various alternate embodiments. Referring specifically to FIG.5c , the fluted media 140 can be provided having a radius r₁ at the peak145 that can be considered a relatively sharp radius, and can beprovided with a radius r₂ at the peak 146 that can be considered arelatively sharp radius. The radius r₁ and the radius r₂ can be the sameor different. Furthermore, the benefits of reduced masking can beachieved by providing only one of r₁ or r₂ with a relatively sharpradius.

FIGS. 16a and 16b show examples of radii determined on actual filtermedia. Radius can be measured, for example, by a methodology that uses ameasure called the local effective inner radius. Local effective innerradius is defined as the minimum outer radius of curvature at a givenflute tip, peak, or ridge, minus the average media thickness of theflute. The minimum outer radius of curvature is the smallest radius ofcurvature of an osculating circle fitting the curve formed by followingthe outermost surface of a cross section of a given flute tip, peak, orridge. For reference, the osculating circle of a sufficiently smoothplane curve at a given point on the curve is the circle whose centerlies on the inner normal line and whose curvature is the same as that ofthe given curve at that point. Graphical examples of measures of localeffective inner radius are shown in FIGS. 16a and 16 b.

In the alternative, a formula that can be used to describe an acceptableradius (for certain embodiments) is based on flute width (D1) and mediathickness (T). An example formula that can be used to describe theradius at the peak that can be characterized as a relatively sharpradius is (D1−2T)/8 wherein the flute width D1 is greater than about 1mm and less than about 4 cm, and the thickness (T) is greater than about0.127 mm (0.005 inch) and less than one half of D1. Preferably, arelatively sharp radius has a radius of less than about (D1−2T)/16.

Now referring to FIGS. 17 and 18, a portion of a filtration media packis shown at reference number 400 in a cylindrical arrangement 402. Thefiltration media pack includes a first face 404 and a second face 406.For the cylindrical arrangement 402, the first face 404 can beconsidered the inner surface of the cylindrical arrangement, and thesecond face 406 can be considered the outer surface of the cylindricalarrangement. The first face 404 can be provided having the relativelylarge openings 405 and the second face 406 can be provided having therelatively small openings 407. When the filtration media pack 402 isfanned, enhanced spacing is provided between the pleats at the secondface 406. As a result, the arrangement shown in FIGS. 17 and 18 can beadvantageous when dirty air flows into the filtration media pack via thesecond flow face 406 and exits the filtration media pack via the firstflow face 404.

By fanning the filtration media pack, enhanced separation between themedia surfaces and enhanced media area (as a result of a lack ofmasking) can be provided for receiving the dirty air, and a relativelylarge volume can be provided as the downstream or clean side volume sothat the fluid can flow out of the filtration media pack with reducedrestriction. As a result of the cylindrical arrangement 402, therelatively larger volume (calculated as media asymmetric volume) can beprovided on the side open to the inner surface, and the relativelysmaller volume can be provided on the side open to the outer surface

Filtration Media

The filtration media can be provided as a relatively flexible media,including a non-woven fibrous material containing cellulose fibers,synthetic fibers, glass fibers, or combinations thereof, often includinga resin therein, and sometimes treated with additional materials. Anexample filtration media can be characterized as a cellulosic filtrationmedia that can tolerate about up to twelve percent (12%) strain withouttearing when wet and warm, but which will rupture at lower percentstrain when dry and cold (as low as 3% with some media). The filtrationmedia can be fluted into various fluted shapes or patterns withoutunacceptable media damage and can be pleated to form pleated filtrationmedia. In addition, the filtration media is desirably of a nature suchthat it will maintain its fluted configuration, during use. While somefiltration media is available that can tolerate greater than abouttwelve percent (12%) strain, and such media can be used according to theinvention, that type of media is typically more expensive because of theneed to incorporate relatively large amounts of synthetic fibers.

In the fluting process, an inelastic deformation is caused to the media.This prevents the media from returning to its original shape. However,once the forming displacements are released, the flutes will sometimestend to spring partially back, recovering only a portion of the stretchand bending that has occurred. Also, the media can contain a resin.During the fluting process, the media can be heated to soften the resin.When the resin cools, it will help to maintain the fluted shapes.

The filtration media can be provided with a fine fiber material on oneor both sides thereof, for example, in accord with U.S. Pat. Nos.6,955,775, 6,673,136, and 7,270,693, incorporated herein by reference intheir entirety. In general, fine fiber can be referred to as polymerfine fiber (microfiber and nanofiber) and can be provided on the mediato improve filtration performance. As a result of the presence of finefiber on the media, it can be possible to provide media having a reducedweight or thickness while obtaining desired filtration properties.Accordingly, the presence of fine fiber on media can provide enhancedfiltration properties, provide for the use of thinner media, or both.Fiber characterized as fine fiber can have a diameter of about 0.001micron to about 10 microns, about 0.005 micron to about 5 microns, orabout 0.01 micron to about 0.5 micron. Exemplary materials that can beused to form the fine fibers include polyvinylidene chloride, polyvinylalcohol polymers, polyurethane, and co-polymers comprising variousnylons such as nylon 6, nylon 4,6, nylon 6,6, nylon 6,10, andco-polymers thereof, polyvinyl chloride, PVDC, polystyrene,polyacrylonitrile, PMMA, PVDF, polyamides, and mixtures thereof.

Several techniques can be relied upon for enhancing the performance ofpleated filtration media. The technique can be applied to pleatedfiltration media used in panel filter arrangements and for pleatedfiltration media used in cylindrical or conical filter arrangements.Depending on whether the pleated filtration media is intended to be usedin a panel filter arrangement or a cylindrical or conical filterarrangement, alternative preferences can be provided. In view of thisdisclosure, one would understand when certain preferences are moredesirable for a panel filter arrangement and when certain preferencesare more desirable for a cylindrical filter arrangement.

Accordingly, it should be understood that the identification of apreference is not intended to reflect a preference for both panel filterarrangements and cylindrical filter arrangements. Furthermore, it shouldbe understood that the preferences may change as a result of whether thecylindrical filter arrangement is intended to be an arrangement that canbe characterized as a forward flow arrangement (where dirty air flowsinto the filter media pack from the exterior cylindrical surface) or areverse flow filtration media pack (where dirty flows into thefiltration media pack from the inner surface of the filtration mediapack).

Filter Elements

The following filter elements are provided as examples constructed inaccordance with the present invention, and are not intended to be allinclusive of element designs made in accordance with the teachingsherein. Rather, one of skill in the art will appreciate that variousalternative elements can be constructed while still within the scope ofthe disclosure and claims. In FIG. 19, a panel filter 300 is depicted.The panel filter 300 comprises media 301, pleated in a configurationcomprising pleat folds 302. The panel 300 depicted includes a frameconstruction 310 having a seal arrangement 312 thereon. The sealarrangement 312 is generally configured to form a seal with a housing orother structure in which the panel filter 10 is positioned. The panelfilter 300 also includes a support grid 314, across one surface of thepanel filter arrangement 300.

While there are variations in panel filters from those shown in FIG. 19,in general the features are analogous, comprising: a plurality ofparallel pleats; a seal arrangement secured within the panel filter;and, a rectangular configuration with one set of pleat folds 316 in aplane and the second set of pleat folds 318 in a separate plane. (Endsor opposite edges 320 of the pleats can be closed by sealant, or bybeing encased in a mold or frame, if desired.) Although not depicted inFIG. 19, flutes in the pleated media will often run substantiallyperpendicular to pleat folds 316 and 318 (although othernon-perpendicular directions are also envisioned). Thus, the flutes canextend in a direction from pleat folds 316 to pleat folds 318.

In other arrangements, the pleated media is configured or arrangedaround an open central area. An example of such a filter arrangement isdepicted in FIGS. 20 and 21. Referring to FIG. 20, a filter arrangement330 is depicted. The filter arrangement 330 comprises first and secondend caps 332 and 334 having pleated media 336 extending therebetweeen.The pleats of the pleated media 336 generally extend in a directionbetween the end caps 332 and 334. The particular filter arrangement 330of FIG. 20 has an outer liner 340, shown broken away at one location,for viewing pleats. (Typically, although pleats can be viewed throughthe liner 340, the arrangement 330 is simply not drawn that way, forconvenience.) The outer liner 340 shown comprises expanded metal,although a variety of alternative outer liners, including plastic ones,can be used. In some instances, an outer liner is simply not used.Attention is also directed to FIG. 21, which is a side elevational viewof arrangement 330, showing end caps 332 and 334. Pleat folds 336 areshown, as is outer liner 340. For the particular arrangement 330 of FIG.20, a direction perpendicular to the pleat direction is generally acircumference of the filter arrangement 330, indicated by the doubleheaded arrow 342.

The particular filter arrangement 330 depicted is generally cylindrical,although alternatives are possible. Typically, such elements as element330 have an open end cap, in this instance corresponding to end cap 332,and a closed end cap, in this instance corresponding to end cap 334,although alternatives are possible. The term “open” when used inreference to an end cap, is meant to refer to an end cap which has anopen central aperture 344 to allow air flow between an interior space346 of the filter arrangement 330 and the exterior, without passagethrough the media 336. A closed end cap, by comparison, is an end capwhich has no aperture therein. Although not depicted, flutes willtypically be arranged in a direction from outer pleat folds of thepleated media 336 perpendicularly (or near perpendicularly) into theinterior of the element toward the inner volume 346. However, it will beunderstood that the flutes do not have to run perpendicular to the outerpleat folds.

A variety of arrangements have been developed for end caps 332 and 334.The end caps may comprise polymeric material molded to the media.Alternatively they may comprise metal end caps or other preformed endcaps secured to the media, with an appropriate adhesive or pottingagent. The particular depicted end caps 332 and 334 are molded end caps,each comprising compressible foamed polyurethane. End cap 332 is shownwith a housing seal 350, for sealing the element 330 in a housing duringuse. The depicted seal 350 is an inside radial seal, although outsideradial seals and axial seals are also possible.

It is noted that the element may include an inner liner 352 extendingbetween end caps 332 and 334 along an inside of the media 330 as shownin FIG. 20, although in some arrangements such liners are optional. Theinside liner, if used, can be metal, such as expanded metal orperforated metal, or it can be plastic.

The distance between the outside cylindrical surface and the insidecylindrical surface, defined by outer and inner pleat folds, isgenerally referenced as the pleat depth. (An analogous distance is pleatdepth in panel filters, FIG. 19, or in conical filters, FIG. 20.)

An arrangement such as that depicted in FIGS. 20 and 21 are sometimesreferenced herein as a “cylindrical arrangement,” using “cylindricallyconfigured” media, or by similar characterizations. Not all filterarrangements that utilize a tubular media are configured as cylinders.An example of this is illustrated in FIG. 22. Referring to FIG. 22, afilter arrangement 400 comprises extension of media 402 which ispleated, with pleat direction extending in the directions of arrow 404.Filter arrangement 400 is somewhat conical having a wide end 406 and anarrow end 408. At wide end 406 is positioned an end cap 407, and atnarrow end 408 is positioned an end cap 409. As with the cylindricalarrangement, a variety of open and closed end caps can be used. For thespecific example depicted, end cap 407 is open and end cap 408 isclosed.

Filter arrangement 400 includes outer support screen 410 extendingbetween end cap 407 and 409. The particular arrangement 400 includes noinner support screen although one could be used. The filter element 400includes a seal arrangement 412, in this instance an axial seal,although an inside or outside radial seal is possible. Element 400includes a non-continuously threaded mounting arrangement, 414, formounting a housing. The arrangement 400 is generally described in detailin PCT/US2003/33952 filed Oct. 23, 2003, incorporated herein byreference.

Now referring to FIGS. 23 and 24, a filter arrangement is shown asreference number 500. The filter arrangement 500 can be considered to bea type of conical filter element and/or a type of panel filter element.The filter element 500 is shown having a first face 502 and a secondface 504, with pleated media 506 extending between the first face 502and the second face 504. Flutes constructed in accordance with thediscussion herein will typically be arranged directionally between thefirst and second faces 502, 504. The first face 502 includes a screen503, and the second face 504 includes a screen 505. The filter element500 includes a first side 510, second side 512, first end 514, andsecond end 516. The first side 510 and the second side 512 include apotting material 520 that help seals the sides of the pleated media 506,and a seal 522 that prevents fluid from bypassing the media 506 when theelement 500 is arranged in an air cleaner. The first end 514 and thesecond end 516 seal the ends of the pleated media faces, and includeguide pins 530 that help align the element 500 within the air cleaner.

The filter element 500 shown can be considered conical because theradius R1 is different than the radius R2. In general, the radius R1refers to the radius at the first side 510 and the radius R2 refers tothe radius at the second side 512. Although the filter element 500 isshown having a conical structure, it is possible for the radiuses R1 andR2 to be the same so that the filter element more closely resembles apartial cylindrical arrangement or, alternatively, as a bowed panelarrangement.

The filter elements can be utilized in various housing arrangements, andthe filter elements can be replaced or cleaned or refurbishedperiodically, as desired. In the case of air filtration, the housing canbe provided as part of an air cleaner for various air cleaning orprocessing applications including engine air intake, turbine intake,dust collection, and heating and air conditioning. In the case of liquidfiltration, the housing can be part of a liquid cleaner for cleaning orprocessing, for example, water, oil, fuel, and hydraulic fluid.

EXAMPLES

The following examples are provided to help illustrate the disclosure,and should not be considered as limiting with respect to the disclosure.

Filter elements having pleated media were compared using filterperformance modeling software. The filter elements were not constructedand tested for the depicted examples. Instead, variables such as thedimensions of the filter elements and the filter element components, theproperties and characteristics of the filter elements and the filterelement components, the conditions of use, and the characteristics ofthe air being filtered were input into a computer program that modelsfilter performance. The filter performance modeling software is expectedto provide guidance with respect to relative filter element designperformance, but it is expected that actual filter performance willvary.

For each example, the variables used for input into the computer programare identified. In the context of air filters for removing particulatesfor engine air intake, two of many parameters are typically consideredwhen evaluating potential performance. These are initial pressure dropand system life. System life is the capacity of a filter element to holddust to a given limit pressure drop (e.g., grams capacity to a finalpressure drop of 25 inches of water column height). It will beappreciated that although dust is used as the contaminant for theexamples described herein, filter elements made in accordance with thepresent teachings will typically remove numerous contaminants besidesdust, and therefore dust is used only as an example contaminant fordemonstrative and comparative purposes.

The examples compare the performance of one filter element design toanother filter element design, wherein the filter element designs weremodeled, holding the design parameters in the filter element constant,and then varying one design parameter at a time.

For the following examples, the pleated panel filter elements that weremodeled had a dimension of 10 inches wide by 10 inches wide by 1.5inches deep. The media was held constant as a typical productioncellulose media found on many pleated media engine air filterapplications of Donaldson Company, Inc., headquartered in Bloomington,Minn. The media was characterized as having a thickness (T) of 0.0132inch. In addition, the volume flow rate of air to the modeled filterelement was held constant, and the dust type fed to the modeled filterelement was ISO Fine. In the various examples, several parameters wereheld constant and other parameters were varied as identified.

It should be understood that media pack performance changes depending ontest conditions selected and the media and arrangement selected.

Example 1

This example was modeled to evaluate the effect of flute packing densityon initial filter pressure drop and filter life for a specified fluteshape. The flutes are formed from successive 180 degree linked arcs offilter media as shown in FIG. 25. For this example:

T is the media thickness (selected as 0.0132 inch);

J is the flute height;

D1 is the flute width;

D2 is the media length corresponding to the flute width

C is the flute depth (J minus T);

R is the inner radius of the flute (the radius is the same for adjacentpeaks), which is metric for evaluating flute shape;

Again, PCMax is the maximum pleat count concentration at which the panelcan be manufactured without deforming the flutes. In general, PCMaxrefers to the maximum number of pleats that can be placed in a givenvolume before performance suffers as a result of deformation of theflutes. This implies that in a panel configuration modeled, flute peakson adjacent media faces will touch along substantially their entirelength. For panel filters, PCMax pleat concentration is equal to 1/(2J).This implies that for a fixed volume flow rate of air to the filter, asJ changes, the pleat count will change and the media area and the mediaface velocity (the average velocity of airflow through the filter media)will change.

This example was modeled at PCMax, at a filter element volume flow rateof 489.7 cubic feet per minute (cfm), and wherein the upstream (dirtyside) media pack volume equals the downstream (clean side) media packvolume. The flutes are assumed to have a shape that can be characterizedas a 180° arc-arc flute, which means that as the media curves from onepeak it then curves into another adjacent peak without a straightsection between the curves. The radius (R) can be referred to as themaximum radius that maintains the arc-arc flute shape. The results arereported in Table 1 and are graphically represented in FIG. 25 as solidcircles. In addition, small scale representations of the flute shapesare shown in FIG. 25 along corresponding solid circles.

As is evident from Table 1 and FIG. 25, as radius decreases, Jdecreases, D1 also decreases, PcMax increases. For the media andconditions modeled, one of the best filter lives with a low initialpressure drop is provided when the J value is 0.064 inch and R is 0.019inches. Thus, a lower R value corresponds generally to favorable initialpressure drop and filter life.

TABLE 1 Initial PcMax Pressure Drop Life to 25 in J (in) D1 (in) (1/in)R (in) (in H2O @ 60° F.) H2O (gm) 0.045 0.06 11.00 0.010 3.82 213 0.0640.10 7.80 0.019 2.53 185 0.083 0.14 6.04 0.028 2.51 136 0.101 0.18 4.930.037 2.72 100 0.120 0.21 4.17 0.047 3.01 74 0.139 0.25 3.60 0.056 3.3357 0.157 0.29 3.18 0.065 3.68 45 0.176 0.36 2.84 0.075 4.03 36 0.1950.36 2.57 0.084 4.39 30 0.213 0.40 2.35 0.093 4.76 25

Example 2

This example is introduced to show the effect of altering the radius (R)at fixed flute height (J) and flute width (D1).

In this example, J was held constant at 0.083 inch and D1 was heldconstant at 0.14 inch, PCMax was thus held constant and the dirty sidevolume was equal to the clean side volume (i.e. there was no mediavolumetric asymmetry). A first flute shape was selected based upon oneof the designs presented in Example 1. As the radius varied, the flutedesign moved away from the arc-arc shape reported in Example 1 andtoward an arc-flat-arc shape characterized by two arcs separated by aflat area of media with successively sharper flute peaks. The radius onadjacent flute peaks was modeled to be the same. The results of thisexample are reported in Table 2 and graphically represented in FIG. 26as solid diamonds. In addition, small scale representations of the fluteshapes are shown in FIG. 26 along corresponding solid diamonds.

As the radius (R) decreases, initial pressure drop decreases, and lifeincreases. In general, a smaller radius is preferred. This example showsthe value of sharp flute peaks and reduced media masking.

TABLE 2 Media Cord Initial Pressure Life to 25 Percentage Drop (in H2O @in H2O R (in) D2/D1 (%) 60° F.) (gm) 0.001 1.43 1.3 2.16 154 0.004 1.441.9 2.20 149 0.007 1.45 2.6 2.25 144 0.010 1.46 3.3 2.29 140 0.013 1.474.1 2.33 137 0.016 1.48 5.0 2.37 134 0.019 1.50 6.0 2.40 133 0.022 1.527.2 2.44 132 0.025 1.54 8.8 2.47 132 0.028 1.57 10.9 2.51 135

Example 3

This example is presented to show the effect of varying the flute width(D1). The flute shape begins with the flute shape from Table 2 reportedhaving a flute height (J) of 0.083 inch, a radius (R) of 0.010 inch, anda flute width (D1) of 0.14 inch. While flute height and radii were heldconstant, the flute width was allowed to vary. The results of thisexample are reported in Table 3 and graphically represented in FIG. 27as solid triangles. In addition, simplified cross sections of the fluteshapes are illustrated in FIG. 27.

In general, in this example, as the flute width (D1) increases, initialpressure drop decreases, life decreases, and the ratio D2/D1 decreases.Increasing the flute width (D1) relative to the flute height and radiusis valuable to provide a low initial pressure drop. However, in thisexample, filter life was shown to decrease.

TABLE 3 Initial Pressure Life to 25 D1 D2/D1 Media Cord Drop (in H2O inH2O (in) (%) Percentage (%) @ 60° F.) (gm) 0.14 1.46 3.2 2.28 139 0.181.28 1.6 2.14 118 0.22 1.19 0.8 2.05 109 0.26 1.14 0.5 1.99 105 0.3 1.110.3 1.95 103 0.34 1.08 0.2 1.92 102 0.38 1.07 0.1 1.90 101 0.42 1.05 0.11.88 100 0.46 1.05 0.1 1.87 99 0.50 1.03 0 1.86 99

Example 4

This example shows the effect of media volume asymmetry. The flute shapechanged from an arc-flat-arc flute shape to a flute shape similar tothat shown in FIG. 5A. In general, the flute height (J), the flutelength (D1), and the peak radius (R) were held constant. J was heldconstant at 0.083 inch, D1 was held constant at 0.14 inch, and R washeld constant at 0.01. The media pack was maintained at PCMax which was6.04 1/inch. In addition, the value L was held constant at 0.03 inch. Ascan be seen in FIG. 5a , for a shape according to one of theimplementations of this invention defined mathematically by arcs andflats, L is the flute length distance parallel to the line defined byD1, from the outside surface of the media at the peak 103 to the tangentof the ridge 108, and the value H refers to the height differencebetween the locations used to measure L. In this example, H was varied.

The results are shown in Table 4 and are graphically represented in FIG.28 as plus signs. In addition, the flute shapes are also shown. As mediavolume asymmetry varied, filter life also varied, with the best modeledfilter life occurring with media having a media volume asymmetry of 157%to 174%. It will be understood that different media configurations willhave different results, but also that media volume asymmetry can be animportant mechanism for improving filter life.

TABLE 4 Media Initial Volume Media Cord Pressure Life to 25 H AsymmetryPercentage Drop (in in H2O (in) (%) D2/D1 (%) H2O @ 60° F.) (gm) 0.004221 1.63 14.9 3.23 126 0.005 207 1.61 13.6 2.98 140 0.006 194 1.59 12.32.81 148 0.007 183 1.57 11.2 2.69 152 0.008 174 1.56 10.1 2.60 154 0.009165 1.54 9.1 2.53 154 0.010 157 1.53 8.2 2.47 154 0.011 150 1.52 7.42.43 153 0.012 143 1.51 6.7 2.40 151 0.013 137 1.50 6.1 2.37 150 0.014132 1.49 5.5 2.35 148 0.015 127 1.49 5.0 2.34 146 0.016 123 1.48 4.62.33 145 0.017 119 1.48 4.3 2.32 144 0.018 116 1.47 4.0 2.31 143 0.019112 1.47 3.8 2.30 142 0.020 109 1.47 3.6 2.30 141 0.021 107 1.46 3.52.30 141 0.022 104 1.46 3.4 2.29 140 0.023 102 1.46 3.3 2.29 140 0.024100 1.46 3.3 2.29 140 0.025 98 1.46 3.3 2.29 140 0.026 96 1.46 3.3 2.29140 0.027 94 1.46 3.4 2.29 140 0.028 92 1.46 3.5 2.29 141

Example 5

This example repeats Example 2 except that it begins at a differentpoint. Again, this example is to show the effect of altering the radius(R) at fixed flute height (J) and flute width (D1). For this example,the flute height (J) is 0.064 inch, the flute period length (D1) is 0.10inch, and PCMax is 7.80 1/inch.

The results of this example are reported in Table 5 and also graphicallyrepresented in FIG. 28 as solid squares. For comparative purposes, theresults of Example 2 are plotted as hollow squares. This example showsincreases in filter life as radius is decreased. This example againshows the value of sharp flute peaks and reduced media masking.

TABLE 5 Media Cord Initial Pressure Life to 25 Percentage Drop in H2O R(in) D2/D1 (%) (in H2O @ 60° F.) (gm) 0.001 1.44 1.9 2.14 214 0.003 1.452.5 2.18 207 0.005 1.46 3.1 2.23 200 0.007 1.47 3.8 2.27 194 0.009 1.484.6 2.31 190 0.011 1.49 5.4 2.35 186 0.013 1.50 6.4 2.39 183 0.015 1.527.6 2.44 182 0.017 1.54 9.0 2.48 182 0.019 1.57 11.0 2.53 185

Example 6

This example was carried out according to Example 3, except that theflute height (J) is 0.064 inch, R is 0.01 inch, PCMax is 7.80 1/inch.Again, this example is presented to show the effect of varying the flutewidth (D1).

The results of this example are reported in Table 6 and also graphicallyrepresented in FIG. 28 as solid triangles. For comparative purposes, theresults of Example 3 are plotted as eight-pointed “stars”. This exampleagain shows decreases in filter life and initial pressure drop as flutewidth increased.

TABLE 6 Media Cord Initial Life to 25 Percentage Pressure Drop in H2O D(in) D2/D1 (%) (in H2O @ 60° F.) (gm) 0.10 1.50 5.3 2.36 190 0.13 1.292.2 2.06 161 0.17 1.18 1.1 1.91 153 0.20 1.13 0.6 1.81 152 0.23 1.09 0.31.76 152 0.27 1.07 0.2 1.72 151 0.30 1.06 0.1 1.69 151 0.33 1.05 0.11.67 151 0.37 1.04 0.1 1.66 151

Example 7

This example was carried out according to Example 4 except that theflute height (J) is 0.064089 inch, the flute length (D1) is 0.1018 inch,PCMax is 7.801651 1/inch, R is 0.01 inch, and L is 0.023 inch. H wasallowed to vary. Again, the flute shape changed from an arc-flat-arcflute shape to a flute shape similar to that shown in FIG. 5A.

The results of this example are reported in Table 7 and graphicallyrepresented in FIG. 28 as solid diamonds. For comparative purposes, theresults of Example 4 are plotted as “plus signs”. This example againshows that media volume asymmetry can be an important mechanism forimproving filter life.

TABLE 7 Initial Life to 25 Media Volume Pressure Drop in H2O H (in)Asymmetry (%) D2/D1 (in H2O @ 60° F.) (gm) 0.005 192.67 1.64 3.20 2070.006 175.02 1.61 2.92 213 0.007 160.34 1.58 2.72 213 0.008 148.09 1.562.59 210 0.009 137.63 1.54 2.50 206 0.010 128.85 1.52 2.44 201 0.011121.45 1.51 2.40 196 0.012 115.24 1.50 2.37 193 0.013 110.10 1.49 2.35190 0.014 105.91 1.49 2.34 189 0.015 102.60 1.49 2.34 188 0.016 100.131.49 2.33 187 0.017 97.98 1.49 2.33 188 0.018 95.55 1.49 2.33 188

In reference now to FIG. 29, dust loading performance data from tests oftwo example configurations of media are depicted, with dust loading(grams of Iso Fine) plotted against pressure differential across theelement. Element 1 was constructed with the best of our currenttraditionally corrugated media, while Element 2 was constructed usingfluted media constructed in accordance with the invention. As is evidentfrom FIG. 29, the media constructed in accordance with the inventiondemonstrated a significant improvement in dust loading.

The above specification provides a complete description of the presentinvention. Since many embodiments of the invention can be made withoutdeparting from the spirit and scope of the invention, the inventionresides in the claims hereinafter appended.

I claim:
 1. A filter element comprising: filter media defining aplurality of pleats extending between a first set of pleat foldsdefining a first flow face and a second set of pleat folds defining asecond flow face in a back and forth arrangement, the filter elementdefining an upstream side having the first flow face and a downstreamside having the second flow face, the filter media defining a pluralityof flutes extend along the pleats between the first face and the secondface, wherein the plurality of flutes are perpendicular to the first setof pleat folds and the second set of pleat folds, wherein each flute hasa central flute peak along the flute, wherein the flute peak extendsbeyond the general profile of the flute, and wherein the flutes definedby adjacent pleats of filter media cooperatively define an upstreamvolume there-between to accommodate fluid flow into the filter elementthrough the first face.
 2. The filter element of claim 1, wherein theflutes defined by adjacent pleats of filter media further cooperativelydefine a downstream volume there-between to accommodate fluid flow intothe filter element through the second face, and wherein the flutesdefined by adjacent pleats of filter media have flute peaks that faceeach other and touch along their length.
 3. The filter element of claim1, wherein the flute height is relatively constant along the flutelength.
 4. The filter element of claim 1, wherein the flutes taper alongthe flute length.
 5. The filter element of claim 1, wherein at least aportion of the flutes have a flute height that changes over the flutelength.
 6. The filter element of claim 1, wherein the filter mediadefines at least one ridge between adjacent flute peaks, wherein eachridge is a line of intersection between differently-sloped mediaportions.
 7. The filter element of claim 1, wherein at least a portionof the flutes extending from the first set of pleat folds to the secondset of pleat folds comprise a D2/D1 value of at least 1.05, wherein D2is the media length corresponding to the flute width, and D1 is theflute width.
 8. The filter element of claim 1, wherein the flutesexhibit width to height aspect ratio (D1/J) of at least about 2.0. 9.The filter element of claim 1, wherein the flutes exhibit a D2/D1 valueof at least 1.1, wherein D2 is the media length corresponding to theflute width, and D1 is the flute width.
 10. The filter element of claim1, wherein the filtration media exhibits a media volume asymmetry of atleast 10%.
 11. The filter element of claim 1, wherein the filtrationmedia exhibits a media asymmetric volume arrangement so that a volume onone side of the media is greater than a volume on the other side of themedia by at least 50%.
 12. The filter element of claim 1, wherein themedia has a media cord percentage of at least 5%.
 13. The filter elementof claim 1, wherein the filtration media has at least one cross sectionwherein the flutes have media cross-sectional area asymmetry of at least10%.
 14. The filter element of claim 1, wherein the flutes exhibit awidth to height aspect ratio of at least 4.0.
 15. The filter element ofclaim 1, wherein at least 25% of the flutes in the filter elementcomprise at least two ridges between adjacent flute peaks and extendingalong at least 25% of the flute length between the first set of pleatfolds and the second set of pleat folds.
 16. The filter element of claim1, wherein the first face and the second face are non-planar.
 17. Thefilter element of claim 1, wherein the flutes extend at an angle ofabout 60 degrees to about 150 degrees relative to one of the first faceor the second face.
 18. The filter element of claim 1, wherein the firstface and the second face are substantially planar.
 19. The filterelement of claim 1, wherein the first face and the second face arenon-parallel.